Chevrolet - K Tahoe 4wd - Workshop Manual - 2002 - 2002

Factory Workshop Manual Make Chevrolet Model K Tahoe 4wd Engine and year V8-5.3L VIN T (2002) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 16 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 17 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 18 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 19 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 20 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 21 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 22 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 23 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 24 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 25 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 26 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 27 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 28 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 29 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 30 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 31 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 32 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 33 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 34 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 35 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 36 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 37 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 38 Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) POWER MODE RAP is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its shut-off limit. The body control module monitors the ignition switch position, battery condition and passenger compartment door status to determine whether RAP should be initiated. If the ignition switch transitions from RUN/ON to OFF, the battery level is within the acceptable range and the passenger compartment doors are closed, the body control module closes the RAP relay. This provides power for the following: ^ Sunroof ^ Power windows ^ Power door locks ^ Radio ^ Rear radio ^ OnStar The BCM turns OFF the RAP function and opens the RAP relay when one of the following conditions are met: ^ The BCM senses the opening of any door or the liftgate. ^ The BCM detects a decrease in battery capacity below a prescribed limit. ^ The BCM receives a message from its internal timer indicating the end of the RAP period after 20 minutes. ^ The transition from OFF to RUN/ON or ACC of the ignition switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Accessory Delay Module Begin the system diagnosis with the Diagnostic System Check Accessory Delay Module. The Diagnostic System Check will provide the following information: ^ The identification of the control module which commands the system ^ The ability of the control module to communicate through the serial data circuit ^ The identification of any stored DTCs and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Accessory Delay Module DIAGNOSTIC SYSTEM CHECK - ACCESSORY DELAY MODULE TEST DESCRIPTION Steps 1-5 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. This step is checking for DTCs in the BCM. 5. This step is checking for RAP specific DTCs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 41 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms - Accessory Delay Module IMPORTANT PRELIMINARY CHECKS BEFORE STARTING 1. Perform the Diagnostic System Check - Retained Accessory Power before using the Symptom Tables in order to verify that all of the following are true: ^ There are no DTCs set. ^ The control module(s) can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check - Accessory Delay Module 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory Power (RAP) Description and Operation. VISUAL/PHYSICAL INSPECTION ^ Inspect for aftermarket devices which could affect the operation of the Retained Accessory Power system. Refer to Checking Aftermarket Accessories in Diagnostic Aids. ^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in Diagnostic Aids. SYMPTOM LIST Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: ^ Retained Accessory Power (RAP) On After Timeout ^ Retained Accessory Power (RAP) Inoperative Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 42 Steps 1-10 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 43 Steps 1-9 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 44 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions MODULE INFORMATION 1 Julian Date of Build: The scan tool displays the date upon which the Body Control Module (BCM) was manufactured. Manufacture Enable Counter (MEC): The scan tool displays the actual value for the MEC in the BCM. This information is for the assembly plant only. Module Part Number: The scan tool displays the part number assigned to the BCM that is currently in the vehicle. Software Design Suffix: The scan tool displays the version of the software part number in the BCM. Software Part Number: The scan tool displays the software identification number (ID) in the BCM. MODULE INFORMATION 2 Retained Accessory Power (RAP) Calibration Number: The scan tool displays the RAP calibration part number in the BCM. Retained Accessory Power (RAP) Suffix: The scan tool displays the RAP identification number in the BCM. DATA Battery Voltage: The scan tool displays the battery system voltage. Inadvertent Power Timer: The scan tool displays the seconds left before the BCM turns the inadvertent power relay OFF. The BCM uses this feature to protect the battery against inadvertent battery rundown caused by components that are part of the courtesy lamp circuit. The inadvertent power relay is supplied power by the BCM for 2400 seconds / 40 minutes after the ignition is turned OFF. RAP Timer: The scan tool displays the seconds left before the BCM turns the RAP relay OFF. The BCM uses this feature to allow the operation of the radio and the power windows for up to 1198 seconds / 20 minutes after the ignition is turned OFF. After the time has elapsed or the door is opened the BCM will open the ground circuit for the RAP relay. INPUT 1 Door Handle Switch: The scan tool displays the position of the door handle. The scan tool displays ACTIVE when a door handle is raised and INACTIVE with all doors closed and the door handles at rest. Drivers Door Jamb Switch: The scan tool displays the position of the drivers door. The scan tool displays ACTIVE when the drivers door is open. Ignition 1: The scan tool displays the position of the ignition switch. The scan tool displays ACTIVE when the ignition switch is in the RUN or CRANK position. Ignition 3: The scan tool displays the position of the ignition switch. The scan tool displays ACTIVE when the ignition switch is in the RUN position only. Ignition Power Mode: The scan tool displays the position of the ignition switch. The scan tool displays OFF, RUN, CRANK and UNKNOWN. The UNKNOWN display is when the BCM can not determine the position of the ignition switch. Key In Ignition: The scan tool displays the position of the ignition key in the ignition switch cylinder. The scan tool displays YES when the ignition key is completely inserted into the ignition switch cylinder. The BCM uses this data in controlling the operation of the reminder chime feature. RAP Relay Feedback: The scan tool displays the state of the RAP relay. The scan tool displays ON when the BCM activates the RAP relay. OUTPUTS RAP Relay: The scan tool displays the commanded state of the RAP relay. The scan tool displays ON when the BCM allows the RAP relay to go to ground. The BCM will allow operation of the radio and the power windows with the ignition OFF and the doors closed for up to 1198 seconds, approximately 20 minutes. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 45 Scan Tool Data List Scan Tool Output Controls Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 49 Theft Deterrent Control Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 50 Alarm Module: Service and Repair THEFT DETERRENT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR. Refer to Disabling the SIR System in Restraint Systems. 2. Remove the steering column trim covers. 3. Remove the ignition lock cylinder. 4. Remove the theft deterrent control module wiring harness from the steering column harness. 5. Disconnect the electrical connector from the theft deterrent control module. 6. If, necessary, disconnect the electrical connector from the ignition lock cylinder case. 7. Remove the theft deterrent module (2) away from the lock cylinder housing (1). INSTALLATION PROCEDURE 1. Install the theft deterrent control module (2), onto the lock cylinder housing (1). 2. Install the theft deterrent control module wiring harness to the steering column harness. 3. If, necessary, disconnect the electrical connector from the ignition lock cylinder case. 4. Connect the electrical connector. 5. Install the ignition lock cylinder. 6. Install the steering column trim covers. 7. Enable the SIR system. Refer to Enabling the SIR System in Restraint Systems. 8. Program the new theft deterrent control module. Refer to Programming Theft Deterrent System Components. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Service and Repair Antenna Control Module: Service and Repair RADIO ANTENNA MODULE REPLACEMENT REMOVAL PROCEDURE The Radio control module and the Radio Antenna module cannot be replaced individually. 1. Lower the rear of the headliner. Refer to Headliner Replacement in Interior Trim. 2. Disconnect the wire harness (2) attached to the rear quarter glass panel. 3. Remove the module (3) retaining bolt. 4. Disconnect the antenna cable from the module. 5. Remove the antenna module from the roof. 6. Remove the radio control module. INSTALLATION PROCEDURE 1. Install the radio control module. 2. Install the antenna module to the roof. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the module retaining bolt. Tighten Tighten the retaining bolt to 9 N.m (80 lb in). 4. Connect the antenna cable to the module (3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Service and Repair > Page 54 5. Connect the wire harness (2) to the rear quarter glass panel. 6. Install the rear of the headliner. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 63 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 64 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 65 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 66 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 67 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 68 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 69 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 70 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 71 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 72 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 73 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 74 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 75 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 76 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 77 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 78 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 79 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 80 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 81 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 82 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 83 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 84 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 85 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 86 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 87 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 88 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 89 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 90 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 91 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 92 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 93 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 94 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 95 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 96 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 102 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 107 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 112 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 113 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 119 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 128 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 129 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 130 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 131 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 132 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 133 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 134 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 135 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 136 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 137 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 138 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 139 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 140 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 141 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 142 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 143 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 144 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 145 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 146 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 147 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 148 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 149 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 150 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 151 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 152 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 153 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 154 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 155 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 156 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 157 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 158 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 159 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 160 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 161 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-64-007A > Sep > 08 > OnStar(R) - Analog Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 178 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 183 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 184 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-007 > Dec > 06 > OnStar - Analog-Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 194 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-64-007A > Sep > 08 > OnStar(R) - Analog Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 215 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 220 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 221 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-007 > Dec > 06 > OnStar - Analog-Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 235 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 236 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 237 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 238 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 239 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 240 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 241 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 242 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 243 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 244 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 245 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 246 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 247 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 248 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 249 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 250 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 251 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 252 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 253 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 254 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 255 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 256 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 257 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 258 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 259 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 260 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 261 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 262 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 263 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 264 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 265 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 266 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 267 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 268 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Service Manual - Revised OnStar(R) VIU & VCU Replacement Global Positioning System Module: Technical Service Bulletins Service Manual - Revised OnStar(R) VIU & VCU Replacement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-46-011 Date: September, 2002 SERVICE MANUAL UPDATE Subject: Revised OnStar(R) Vehicle Interface Unit (VIU) Replacement and OnStar(R) Vehicle Communication Unit (VCU) Replacement Reconfiguration Procedure Models: 2001-2002 Buick LeSabre, Park Avenue 2002 Buick Rendezvous 2001 Cadillac Catera, DeVille, Seville 2001-2002 Cadillac Eldorado 2001 Chevrolet Blazer, Impala, Monte Carlo 2001-2002 Chevrolet Silverado, Suburban, Tahoe, Venture 2001 GMC Envoy, Jimmy 2001-2002 GMC Sierra, Yukon, Yukon XL 2001 Oldsmobile Bravada, Intrigue 2001-2002 Oldsmobile Aurora, Silhouette 2001-2002 Pontiac Aztek, Bonneville, Grand Prix, Montana with Generation 3 OnStar(R) (RPO UE1) This bulletin is being issued to revise the reconfiguration procedure found in the OnStar(R) Vehicle Interface Unit (VIU) Replacement and the OnStar(R) Vehicle Communication Unit (VCU) Replacement procedures in the Cellular Communication sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Due to a new process for configuring replacement Generation 3 (formerly 2.6) OnStar(R) modules for the OnStar(R) Personal Calling feature, vehicles equipped with this version of the system will require a revised OnStar(R) Reconfiguration procedure in the event of module replacement. In addition, the Station Identification Number (STID) and Electronic Serial Number (ESN) numbers are currently accessible by means of the scan tool The procedures for both the Vehicle Interface Unit and Vehicle Communication Unit differ only in which number (STID or ESN) is recorded and transferred to the OnStar(R) Call Center. Important: After replacing the VIU or VCU, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. 1. Press and hold the white Dot button until the OnStar(R) status LED turns from green to red, and back again to green. 2. Install a scan tool. Use the ID information menu to access the new STID (VIU) or ESN (VCU) number. 3. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 4. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center. Tell the advisor that this vehicle has received a new VIU or VCU and ask the advisor to perform the following procedure: 5. Add the new STID (VIU) or ESN (VCU) to update the customer's account. 6. Follow any additional instructions from the OnStar(R) advisor. 7. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Service Manual - Revised OnStar(R) VIU & VCU Replacement > Page 289 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Service Manual - Revised OnStar(R) VIU & VCU Replacement Navigation Module: Technical Service Bulletins Service Manual - Revised OnStar(R) VIU & VCU Replacement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-46-011 Date: September, 2002 SERVICE MANUAL UPDATE Subject: Revised OnStar(R) Vehicle Interface Unit (VIU) Replacement and OnStar(R) Vehicle Communication Unit (VCU) Replacement Reconfiguration Procedure Models: 2001-2002 Buick LeSabre, Park Avenue 2002 Buick Rendezvous 2001 Cadillac Catera, DeVille, Seville 2001-2002 Cadillac Eldorado 2001 Chevrolet Blazer, Impala, Monte Carlo 2001-2002 Chevrolet Silverado, Suburban, Tahoe, Venture 2001 GMC Envoy, Jimmy 2001-2002 GMC Sierra, Yukon, Yukon XL 2001 Oldsmobile Bravada, Intrigue 2001-2002 Oldsmobile Aurora, Silhouette 2001-2002 Pontiac Aztek, Bonneville, Grand Prix, Montana with Generation 3 OnStar(R) (RPO UE1) This bulletin is being issued to revise the reconfiguration procedure found in the OnStar(R) Vehicle Interface Unit (VIU) Replacement and the OnStar(R) Vehicle Communication Unit (VCU) Replacement procedures in the Cellular Communication sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Due to a new process for configuring replacement Generation 3 (formerly 2.6) OnStar(R) modules for the OnStar(R) Personal Calling feature, vehicles equipped with this version of the system will require a revised OnStar(R) Reconfiguration procedure in the event of module replacement. In addition, the Station Identification Number (STID) and Electronic Serial Number (ESN) numbers are currently accessible by means of the scan tool The procedures for both the Vehicle Interface Unit and Vehicle Communication Unit differ only in which number (STID or ESN) is recorded and transferred to the OnStar(R) Call Center. Important: After replacing the VIU or VCU, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. 1. Press and hold the white Dot button until the OnStar(R) status LED turns from green to red, and back again to green. 2. Install a scan tool. Use the ID information menu to access the new STID (VIU) or ESN (VCU) number. 3. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 4. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center. Tell the advisor that this vehicle has received a new VIU or VCU and ask the advisor to perform the following procedure: 5. Add the new STID (VIU) or ESN (VCU) to update the customer's account. 6. Follow any additional instructions from the OnStar(R) advisor. 7. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Service Manual - Revised OnStar(R) VIU & VCU Replacement > Page 294 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams Parking Assist Control Module: Diagrams Rear Object Sensor Control Module Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 298 Rear Object Sensor Control Module Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 299 Parking Assist Control Module: Service and Repair REMOVAL PROCEDURE 1. Lift the right rear seating surface up to gain access to the rear parking aid module. 2. Disconnect the electrical connector from the module. 3. Remove the module retainer. 4. Remove the module from the seat frame. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the module to the seat frame. Tighten Tighten the module retainer to 1.7 N.m (15 lb in). 2. Connect the electrical connector. 3. Lower the seating surface. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 308 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 309 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 310 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 316 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 317 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 318 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Relay Module: > 02-04-21-004 > Apr > 02 > Transfer Case Switch - `Service 4WD' Indicator ON Four Wheel Drive Selector Switch: All Technical Service Bulletins Transfer Case Switch - `Service 4WD' Indicator ON File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-004 Date: April, 2002 TECHNICAL Subject: " "Service 4WD" Indicator Illuminated, DTC B2725 Set (Replace Transfer Case Shift Control Switch) Models: 1999-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Avalanche, Suburban, Tahoe, Yukon, Yukon XL) with Four Wheel Drive and NVG 236/246 Transfer Case (RPO NP8) Condition Some customers may comment on the Service 4WD indicator illuminating. Upon investigation, the technician may find DTC B2725 set. Cause The condition may be due to a intermittent fault in the transfer case shift control switch. Correction Important: The transfer case shift control module should not need replacement. DO NOT replace P/N 15749703 unless diagnosis points to the module as the malfunction. Replace the transfer case shift control switch using published Service Information procedures. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams Power Mirror Control Module: Diagrams Memory Mirror Module Connector C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Page 333 Memory Mirror Module Connector C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Service and Repair > Procedures Power Mirror Control Module: Procedures The mirror relearn procedure, when initiated, commands the Memory Mirror Module (MMM) to control the driver and then the passenger mirror in the left, right, up and down directions. When commanding the mirrors the MMM also learns the direction of horizontal and vertical position sensor signal circuit feedback voltages. To initiate the relearn procedure, perform the following: 1. With a scan tool, select Memory Mirror Module 2. Select Special Functions 3. Select Output Controls 4. Select Mirror Relearn 5. Then press the Reset button If the mirror relearn procedure does not control the driver and passenger mirrors as described, there may be another fault in the mirror systems. Refer to Diagnostic System Check - Door Systems to begin the diagnosis of the mirror system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Service and Repair > Procedures > Page 336 Power Mirror Control Module: Removal and Replacement REMOVAL PROCEDURE 1. Remove the drivers side door panel. 2. Remove the screws (1) that retain the accessory and outside rear view mirror module from the door panel. 3. Remove the nut (2) that retains the accessory and outside rear view mirror module from the door panel. 4. Remove the module from the door panel. INSTALLATION PROCEDURE 1. Install the module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nut (2) that retains the accessory and outside rear view mirror module to the door panel. Tighten Tighten the module retaining nut to 0.6 N.m (5 lb in). 3. Install the screws (1) that retain the accessory and outside rear view mirror module to the door panel. Tighten Tighten the module retaining screws to 0.6 N.m (5 lb in). 4. Install the drivers door panel. 5. Perform the memory mirror module learn procedure. Refer to Memory Mirror Module (MMM) Learn Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 340 Power Seat Control Module: Diagrams Memory Seat Module - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 341 Memory Seat Module - C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 342 Memory Seat Module - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 343 Power Seat Control Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat trim panel. 2. Remove the seal cushion. 3. Disconnect the harness connectors (2). 4. Remove the memory module retaining screws (1). 5. Slide the module out. 6. Remove the module from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 344 1. Slide the module in until seated. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the memory module retaining screws (1). Tighten Tighten the screws to 3 N.m (26 lb in). 3. Connect the harness connectors (2). 4. Install the seat cushion. 5. Install the seat trim panel. 6. It a new memory seat module is installed, the seat needs to be synchronized: 6.1. Operate the seat in all directions: ^ Front tilt ^ Rear tilt ^ Horizontal ^ Recline 6.2. If the seat stops part way due to programmed soft stop, release the switch and operate again in the same direction till the seat touches the mechanical stop 6.3. Repeat the above for all seat moving axes. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 348 Seat Heater Control Module: Diagrams Heated Seat Module - LR Heated Seat Module - RR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof / Moonroof Module: Diagrams Sunroof Module Part 1 Sunroof Module Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Page 352 Sunroof / Moonroof Module: Service and Repair POWER SUNROOF MODULE REPLACEMENT REMOVAL PROCEDURE 1. The sunroof glass panel must be in the closed position. 2. Remove the headliner. 3. Remove the sunroof glass panel. 4. Remove the drain channel. 5. Remove the sunshade. 6. Remove the 9 bolts retaining the module to the roof. 7. Remove the module from the vehicle. INSTALLATION PROCEDURE 1. Install the module to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Page 353 2. Loosely install the 9 bolts retaining the module to the roof. Use a drill bit to align the 2 holes (6 and 7). Tighten Tighten the bolts in the sequence shown to 9 N.m (80 lb in). 3. Install the sunshade. 4. Install the drain channel. 5. Install the sunroof glass panel. 6. Install the headliner. 7. Inspect the operation of the sunroof. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 363 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 369 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 370 Electronic Brake Control Module: Specifications EBCM to BPMV Torx Bolts .................................................................................................................. ................................................. 5 Nm (39 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 371 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 374 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 375 Electronic Brake Control Module: Diagrams C2 - W/O VSES Electronic Brake Control Module (EBCM) - C2 - w/o VSES Part 1 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 376 Part 2 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 377 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 378 Electronic Brake Control Module: Diagrams C2 - W/O VSES Electronic Brake Control Module (EBCM) - C2 - w/o VSES Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 379 Part 1 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 380 Part 2 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 381 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 382 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module (EBCM) Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Electronic Brake Control Module (EBCM) Replacement (w/o JL4) Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. 3. Thoroughly wash all contaminants from around the EHCU (1). 4. Disconnect the electrical connectors from the EBCM. 5. Loosen or remove 3 bolts (4) securing the EHCU mounting bracket (3) to the frame rail (5). 6. Gently move the EHCU down enough to remove the four mounting screws that fasten the EBCM(2) to the BPMV(1). 7. Remove the EBCM (2) from the BPMV (1). Removal may require a light amount of force. 8. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module (EBCM) > Page 385 1. Install the EBCM (2) on to the BPMV(1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four new screws in the EBCM (2). Tighten the four screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Install or tighten three EHCU bracket mounting bolts. Tighten the EHCU bracket mounting bolts to 25 Nm (18 ft. lbs.). 4. Connect the electrical connectors to the EBCM. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 8. Return to Diagnostic Starting Point - Antilock Brake System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module (EBCM) > Page 386 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) (W/JL4) Electronic Brake Control Module (EBCM) Replacement (w/ JL4) Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. 3. Thoroughly wash all contaminants from around the EHCU (1). 4. Disconnect the brake fluid pressure sensor (7) and pressure accumulator switch (4) electrical connectors. 5. Remove the four mounting screws that fasten the EBCM (2) to the BPMV (1). 6. Remove the EBCM (2) from the BPMV (1). Removal may require a light amount of force. Important: Note the routing of the jumper harnesses for reinstallation. 7. Remove the EBCM and jumper harnesses from the vehicle. 8. Remove the jumper harnesses from the EBCM 9. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure 1. Install the jumper harnesses to the EBCM. 2. Install the EBCM and jumper harnesses to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module (EBCM) > Page 387 Important: ^ Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. ^ Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 3. Install the EBCM (2) on to the BPMV (1). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the four new screws in the EBCM (2). Tighten the four screws to 5 Nm (39 inch lbs.) in an X-pattern. 5. Connect the brake fluid pressure sensor (7) and pressure accumulator switch (4) electrical connectors. 6. Lower the vehicle. 7. Connect the negative battery cable. 8. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 9. Return to Diagnostic Starting Point - Antilock Brake System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Diagrams Inverting Driver Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 395 Cruise Control Module (CCM) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 396 Cruise Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the bolts that retain the upper fender brace assembly. 2. Remove the upper fender brace assembly. 3. Disconnect the electrical connector at the cruise control module. 4. Remove the nuts retaining the cruise control module to the cowl. 5. Disconnect the cruise control cable from the module. 6. Remove the cruise control module from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 397 1. Install the cruise control module to the vehicle. 2. Connect the cruise control cable to the cruise control module. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts in order to retain the cruise control module to the cowl. Tighten Tighten the nuts to 9 N.m (8O lb in). 4. Connect the electrical connector at the cruise control module. 5. Install the brace. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 398 Tighten Tighten the bolts to 9 N.m (80 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 406 Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover from the underhood convenience center (1). 2. Remove the compressor relay (2). INSTALLATION PROCEDURE 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 04-01-39-007 > Jun > 04 > A/C Loss of Mode or Temperature Control Control Module HVAC: Customer Interest A/C - Loss of Mode or Temperature Control Bulletin No.: 04-01-39-007 Date: June 17, 2004 TECHNICAL Subject: Loss Of HVAC System Mode and/or Temperature Control (Replace HVAC Control Module) Models: 2002 Cadillac Escalade, Escalade EXT 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalanche 1999-2002 GMC Denali, Sierra, Yukon, Yukon XL 2001 GMC Sierra C3 2002 GMC Sierra Denali with Automatic HVAC System (RPO C68) Condition Some customers may comment that they cannot control the HVAC system modes and/or the temperature. These concerns may be intermittent. Cause An HVAC control module logic lock-up may be the cause of these conditions. Correction Important: Prior to replacing the HVAC control head, review Corporate Bulletin Number 01-01-39-007. Replace the HVAC control module. Refer to the HVAC Control Module Replacement procedure in the HVAC System - Automatic sub-section of the Service Manual. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 04-01-39-007 > Jun > 04 > A/C Loss of Mode or Temperature Control > Page 415 Part Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 04-01-39-007 > Jun > 04 > A/C - Loss of Mode or Temperature Control Control Module HVAC: All Technical Service Bulletins A/C - Loss of Mode or Temperature Control Bulletin No.: 04-01-39-007 Date: June 17, 2004 TECHNICAL Subject: Loss Of HVAC System Mode and/or Temperature Control (Replace HVAC Control Module) Models: 2002 Cadillac Escalade, Escalade EXT 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalanche 1999-2002 GMC Denali, Sierra, Yukon, Yukon XL 2001 GMC Sierra C3 2002 GMC Sierra Denali with Automatic HVAC System (RPO C68) Condition Some customers may comment that they cannot control the HVAC system modes and/or the temperature. These concerns may be intermittent. Cause An HVAC control module logic lock-up may be the cause of these conditions. Correction Important: Prior to replacing the HVAC control head, review Corporate Bulletin Number 01-01-39-007. Replace the HVAC control module. Refer to the HVAC Control Module Replacement procedure in the HVAC System - Automatic sub-section of the Service Manual. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 04-01-39-007 > Jun > 04 > A/C - Loss of Mode or Temperature Control > Page 421 Part Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 422 Blower Motor Control Processor - Auxiliary (Tahoe/Yukon) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic Control Module HVAC: Service and Repair HVAC System - Automatic HVAC Control Module Replacement REMOVAL PROCEDURE 1. Remove the instrument panel accessory trim plate. 2. Remove the screws from the HVAC control module. 3. Depress the control assembly retaining tabs and remove the HVAC control module from the instrument panel. 4. Disconnect the electrical connectors from the HVAC control module. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the HVAC control module. 2. Install the HVAC control module into the instrument panel, ensuring that the HVAC control module retaining tabs lock into place. NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Install the screws to the HVAC control module. Tighten Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 425 Tighten the screws to 1.9 N.m (17 lb in). 4. Install the instrument panel accessory trim plate. Important: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. 5. Start the vehicle and let run for one minute. HVAC Control Module Replacement - Auxiliary REMOVAL PROCEDURE 1. Separate the front of the console (1) from the headliner by pushing forward and pulling down in front. 2. Remove the HVAC control assembly (2) by releasing the tabs at the rear of the control. Push out from the back through the console. 3. Disconnect the electrical connector (3). INSTALLATION PROCEDURE 1. Connect the electrical connector (3). 2. Install the HVAC control assembly (2) to the console (1). 3. Install the console to the headliner. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 426 Control Module HVAC: Service and Repair HVAC System - Manual HVAC CONTROL PROCESSOR REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the auxiliary rear HVAC control assembly. 2. Remove the auxiliary HVAC control processor (2) from the bracket (3). 3. Remove the cover from the auxiliary HVAC control processor (2). 4. Remove the auxiliary HVAC control processor (2) from the box (1). INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 427 1. Install the auxiliary HVAC control processor (2) to the box. (1) 2. Install the cover to the auxiliary HVAC control processor (2). 3. Install the auxiliary HVAC control processor (2) to the bracket (3). 4. Install the auxiliary rear HVAC control assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations System Relay: Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations > Page 431 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-23-004 > Oct > 02 > Brakes 'Reduced Brake Power' Shown on DIC Instrument Panel Control Module: Customer Interest Brakes - 'Reduced Brake Power' Shown on DIC File In Section: 05 - Brakes Bulletin No.: 02-05-23-004 Date: October, 2002 TECHNICAL Subject: Driver's Information Center (DIC) "Reduced Brake Power" Message, Reduced Vacuum Boost (Inspect/Replace Intake Manifold and Recalibrate the Instrument Panel Cluster (IPC)) Models: 2002-2003 Cadillac Escalade 2WD 2002-2003 Chevrolet Avalanche 1500 Series, Silverado, Suburban, Tahoe 2002-2003 GMC Sierra, Yukon, Yukon XL with Power Vacuum Boost Brake System (RPOs JC3 and JC4) Condition Some customers may comment on a "Reduced Brake Power" message on the DIC. Cause It is possible that a very small number of 2002 and 2003 model year vehicles may have a restriction in the vacuum booster port on the intake manifold. On the 2003 model year, only the IPC calibration is the cause of the DIC message. Correction Important: Only inspect suspect vehicles built between June 13, 2002 and August 9, 2002. Follow the service procedure to diagnose and correct this condition. 1. Open the hood and install fender covers. 2. Loosen the engine sight shield bolt. The bolt should stay in the shield. 3. Remove the engine sight shield from the sight shield retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-23-004 > Oct > 02 > Brakes 'Reduced Brake Power' Shown on DIC > Page 441 4. Inspect the left front corner of the intake manifold for a "C" with a circle around it (2). ^ If the intake manifold DOES have a "C" (2) on it, continue with Step 5. ^ If the intake manifold DOES NOT have a "C" (2) on it, continue with Step 19. 5. Disconnect the accelerator control cable clip from the engine sight shield retainer. 6. Disconnect the cruise control cable clip from the retainer if equipped. 7. Remove the engine sight shield retainer bolts and the retainer if equipped. 8. Inspect rear center of the intake manifold just below the recycle symbol for "MADE IN CANADA" (2). ^ If the intake manifold DOES have "MADE IN CANADA" (1) on it, continue with Step 9 ^ If the intake manifold DOES NOT have "MADE IN CANADA" (1) on it, continue with Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-23-004 > Oct > 02 > Brakes 'Reduced Brake Power' Shown on DIC > Page 442 9. Locate the vacuum booster port connector (1) on the left rear of the intake manifold. 10. Gently pull out on the vacuum booster hose (2). 11. With two fingers, push in the vacuum booster port connector lock ring (3) while gently pulling out on the vacuum booster hose (2). Important: ^ DO NOT force the drill bit into the vacuum booster intake port. ^ If the vacuum booster intake port is restricted, DO NOT attempt to remove the restriction with the drill bit. ^ If the restriction is removed with the drill bit, the material from the restriction may cause internal engine damage. ^ If the vacuum booster port is restricted, the intake manifold must be replaced. 12. Inspect the vacuum booster intake port with a 8.7 mm (11/32 in) drill bit, maximum length of 127 mm (5 in). 13. Insert the drill bit approximately 63.5 mm (2.5 in) into the vacuum booster intake port. ^ If the vacuum booster intake port IS restricted, continue with Step 14. ^ If the vacuum booster intake port IS NOT restricted, continue with Step 15. 14. Replace the intake manifold. Refer to Intake Manifold Replacement (SI Document ID # 753666). 15. Reinstall the vacuum booster hose to the vacuum booster intake port by pushing to hose nipple into the connector. 16. Install the engine sight shield retainer and the bolts. Tighten Tighten the engine sight shield retainer bolts to 5 N.m (44 lb in). 17. Install the cruise control cable clip to the retainer. 18. Install the accelerator control cable clip to the retainer if equipped. 19. Install the engine sight shield to the retainer if equipped. Tighten Tighten the engine sight shield bolt to 10 N.m (89 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-23-004 > Oct > 02 > Brakes 'Reduced Brake Power' Shown on DIC > Page 443 20. Start the engine and fully apply the brakes four or five times in order to ensure a "good" brake pedal. Recalibrating the IPC (2003 Model Year Vehicles) 1. Vehicles Built Prior To the following VIN Breakpoints ^ 3G104569 ^ 3E117608 ^ 31118369 ^ 3Z120443 ^ 3R107568 ^ 3J101720 2. Plug in Tech 2. 3. Set the parking brake and turn the ignition ON with the engine off. 4. Reprogram the IPC following normal SPS procedures (TIS Version 9 released August 2002 or newer). 5. After reprogramming the IPC, start the vehicle and fully apply the brakes four to five times in order to ensure a "good" brake pedal and that there are no messages on the DIC. Important: The Owner's Manual Must Be Replaced After The IPC Is Recalibrated. ^ A new Owner's Manual can be ordered from Helm @ 1-800-551-4123. The dealer will be billed for the new Manual and reimbursed through the warranty claims system. ^ The Owner's Manual will be shipped to the dealer. Dealers will be required to mail the Manual to the customer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-23-004 > Oct > 02 > Brakes 'Reduced Brake Power' Shown on DIC > Page 444 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC Instrument Panel Control Module: All Technical Service Bulletins Brakes - 'Reduced Brake Power' Shown on DIC File In Section: 05 - Brakes Bulletin No.: 02-05-23-004 Date: October, 2002 TECHNICAL Subject: Driver's Information Center (DIC) "Reduced Brake Power" Message, Reduced Vacuum Boost (Inspect/Replace Intake Manifold and Recalibrate the Instrument Panel Cluster (IPC)) Models: 2002-2003 Cadillac Escalade 2WD 2002-2003 Chevrolet Avalanche 1500 Series, Silverado, Suburban, Tahoe 2002-2003 GMC Sierra, Yukon, Yukon XL with Power Vacuum Boost Brake System (RPOs JC3 and JC4) Condition Some customers may comment on a "Reduced Brake Power" message on the DIC. Cause It is possible that a very small number of 2002 and 2003 model year vehicles may have a restriction in the vacuum booster port on the intake manifold. On the 2003 model year, only the IPC calibration is the cause of the DIC message. Correction Important: Only inspect suspect vehicles built between June 13, 2002 and August 9, 2002. Follow the service procedure to diagnose and correct this condition. 1. Open the hood and install fender covers. 2. Loosen the engine sight shield bolt. The bolt should stay in the shield. 3. Remove the engine sight shield from the sight shield retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 450 4. Inspect the left front corner of the intake manifold for a "C" with a circle around it (2). ^ If the intake manifold DOES have a "C" (2) on it, continue with Step 5. ^ If the intake manifold DOES NOT have a "C" (2) on it, continue with Step 19. 5. Disconnect the accelerator control cable clip from the engine sight shield retainer. 6. Disconnect the cruise control cable clip from the retainer if equipped. 7. Remove the engine sight shield retainer bolts and the retainer if equipped. 8. Inspect rear center of the intake manifold just below the recycle symbol for "MADE IN CANADA" (2). ^ If the intake manifold DOES have "MADE IN CANADA" (1) on it, continue with Step 9 ^ If the intake manifold DOES NOT have "MADE IN CANADA" (1) on it, continue with Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 451 9. Locate the vacuum booster port connector (1) on the left rear of the intake manifold. 10. Gently pull out on the vacuum booster hose (2). 11. With two fingers, push in the vacuum booster port connector lock ring (3) while gently pulling out on the vacuum booster hose (2). Important: ^ DO NOT force the drill bit into the vacuum booster intake port. ^ If the vacuum booster intake port is restricted, DO NOT attempt to remove the restriction with the drill bit. ^ If the restriction is removed with the drill bit, the material from the restriction may cause internal engine damage. ^ If the vacuum booster port is restricted, the intake manifold must be replaced. 12. Inspect the vacuum booster intake port with a 8.7 mm (11/32 in) drill bit, maximum length of 127 mm (5 in). 13. Insert the drill bit approximately 63.5 mm (2.5 in) into the vacuum booster intake port. ^ If the vacuum booster intake port IS restricted, continue with Step 14. ^ If the vacuum booster intake port IS NOT restricted, continue with Step 15. 14. Replace the intake manifold. Refer to Intake Manifold Replacement (SI Document ID # 753666). 15. Reinstall the vacuum booster hose to the vacuum booster intake port by pushing to hose nipple into the connector. 16. Install the engine sight shield retainer and the bolts. Tighten Tighten the engine sight shield retainer bolts to 5 N.m (44 lb in). 17. Install the cruise control cable clip to the retainer. 18. Install the accelerator control cable clip to the retainer if equipped. 19. Install the engine sight shield to the retainer if equipped. Tighten Tighten the engine sight shield bolt to 10 N.m (89 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 452 20. Start the engine and fully apply the brakes four or five times in order to ensure a "good" brake pedal. Recalibrating the IPC (2003 Model Year Vehicles) 1. Vehicles Built Prior To the following VIN Breakpoints ^ 3G104569 ^ 3E117608 ^ 31118369 ^ 3Z120443 ^ 3R107568 ^ 3J101720 2. Plug in Tech 2. 3. Set the parking brake and turn the ignition ON with the engine off. 4. Reprogram the IPC following normal SPS procedures (TIS Version 9 released August 2002 or newer). 5. After reprogramming the IPC, start the vehicle and fully apply the brakes four to five times in order to ensure a "good" brake pedal and that there are no messages on the DIC. Important: The Owner's Manual Must Be Replaced After The IPC Is Recalibrated. ^ A new Owner's Manual can be ordered from Helm @ 1-800-551-4123. The dealer will be billed for the new Manual and reimbursed through the warranty claims system. ^ The Owner's Manual will be shipped to the dealer. Dealers will be required to mail the Manual to the customer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 453 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 459 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 460 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 461 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 462 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 463 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 464 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 469 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 475 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 476 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 477 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 478 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 479 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 480 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 485 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 491 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 492 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 493 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 494 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 495 Brake Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 496 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 497 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 498 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 499 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 500 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 501 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 502 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 503 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 504 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 505 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 506 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 507 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 508 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 509 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 510 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 511 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 512 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 513 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 514 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 515 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 516 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 517 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 518 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 519 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 520 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions Daytime Running Lamp Control Unit: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 525 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 526 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 527 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 528 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 529 Daytime Running Lamp Control Unit: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 530 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 531 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 532 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 533 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 534 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 535 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 536 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 537 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 538 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 539 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 540 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 541 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 542 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 543 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 544 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 545 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 546 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 547 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 548 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 549 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 550 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 551 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 552 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 553 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 554 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 558 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Daytime Running Lamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 561 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 562 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 563 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 564 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 565 Daytime Running Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 566 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 567 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 568 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 569 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 570 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 571 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 572 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 573 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 574 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 575 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 576 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 577 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 578 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 579 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 580 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 581 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 582 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 583 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 584 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 585 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 586 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 587 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 588 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 589 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 590 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Page 591 Daytime Running Lamp Relay: Service and Repair REMOVAL PROCEDURE 1. Open the electrical center cover (2). 2. Using the relays/fuses diagram, locate the DRL relay. 3. Remove the relay from the underhood electrical center. INSTALLATION PROCEDURE 1. Refer to the diagram for the relays/fuses in the cover locate the position of the relay. 2. Install the relay in the electrical center. 3. Install the cover (2). 4. Start and vehicle and shift gear lever out of park. Ask an assistant to look in front of vehicle to ensure the DRL are operating. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Exterior Lighting Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 596 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 597 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 598 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 599 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 600 Exterior Lighting Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 601 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 602 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 603 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 604 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 605 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 606 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 607 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 608 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 609 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 610 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 611 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 612 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 613 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 614 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 615 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 616 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 617 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 618 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 619 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 620 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 621 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 622 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 623 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 624 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 625 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 626 Roof Beacon Relay Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 630 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Fog/Driving Lamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 633 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 634 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 635 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 636 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 637 Fog/Driving Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 638 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 639 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 640 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 641 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 642 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 643 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 644 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 645 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 646 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 647 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 648 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 649 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 650 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 651 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 652 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 653 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 654 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 655 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 656 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 657 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 658 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 659 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 660 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 661 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 662 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 666 Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions Headlamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 669 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 670 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 671 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 672 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 673 Headlamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 674 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 675 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 676 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 677 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 678 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 679 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 680 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 681 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 682 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 683 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 684 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 685 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 686 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 687 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 688 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 689 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 690 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 691 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 692 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 693 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 694 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 695 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 696 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 697 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 698 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 702 Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Service and Repair Lamp Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the IP trim bezel. 2. Remove the head lamp switch/4WD shift button housing from the IP by pulling outwards. The arrows in the graphic shows the locations of the retaining clips. 3. Disconnect all the electrical connectors. 4. Remove the electrical tape around the lamp module and discard. 5. Remove the lamp module from the connector by pulling outwards. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Service and Repair > Page 706 1. Install the lamp module to the connector until fully seated. IMPORTANT: Do not tape past the line where the cooling fins begin. Taping around the fins will result in the module overheating. 2. Install a new electrical tape around the module in order to secure the module to the IP wire harness. 3. Connect all the electrical connectors. 4. Install the head lamp switch/4WD shift button housing to the IP so that the retainers are fully seated. 5. Install the IP trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Parking Lamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 711 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 713 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 714 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 715 Parking Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 716 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 717 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 718 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 719 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 720 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 721 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 722 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 723 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 724 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 725 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 726 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 727 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 728 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 729 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 730 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 731 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 732 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 733 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 734 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 735 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 736 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 737 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 738 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 739 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 740 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 749 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 750 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 756 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 757 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 762 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 763 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 764 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 765 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 766 Turn Signal Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 767 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 768 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 769 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 770 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 771 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 772 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 773 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 774 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 775 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 776 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 777 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 778 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 779 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 780 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 781 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 782 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 783 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 784 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 785 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 786 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 787 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 788 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 789 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 790 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 791 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 796 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Junction Block - Rear Lamps - C2 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 797 Junction Block - Rear Lamps - C2 Part 2 Junction Block - Rear Lamps - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 798 Junction Block - Rear Lamps - C4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) Relay Box: Service and Repair Relay Replacement (Within an Electrical Center) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views to locate the electrical center where the relay exists. IMPORTANT: Always note the orientation of the relay. - Make sure the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). NOTE: Use J 43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 801 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 802 Relay Box: Service and Repair Relay Replacement (Attached to Wire Harness) REMOVAL PROCEDURE 1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. IMPORTANT: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). INSTALLATION PROCEDURE 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 810 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 811 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 812 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 813 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 814 Body Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 815 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 816 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 817 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 818 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 819 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 820 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 821 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 822 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 823 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 824 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 825 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 826 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 827 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 828 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 829 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 830 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 831 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 832 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 833 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 834 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 835 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 836 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 837 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 838 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 839 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 840 Body Control Module: Connector Views Body Control Module Connector (BCM) - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 841 Body Control Module (BCM) - C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 842 Body Control Module (BCM) - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 843 Body Control Module: Electrical Diagrams Controlled/Monitored Subsystem References Controlled/Monitored Subsystem References Body Control Module Schematics: Controlled/Monitored Subsystem References Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 844 Exterior Lighting Systems References Exterior Lighting Systems References Body Control Module Schematics: Exterior Lighting Systems References Interior Lighting Systems References Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 845 Interior Lighting Systems References Body Control Module Schematics: Interior Lighting Systems References Power, Ground and Serial Data Power, Ground and Serial Data Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 846 Body Control Module Schematics: Power, Ground And Serial Data Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures IMPORTANT: If any module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not properly configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: ^ The battery is fully charged. ^ The ignition switch is in the RUN position. ^ The DLC is accessible. ^ All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: ^ Inspect all BCM connections. ^ Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to the Theft Deterrent sub-system for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve History DTCs from all modules. 5. Clear all history DTCs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 849 Body Control Module: Removal and Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable(s). 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the BCM from the sliding bracket. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 850 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. 4. Install the knee bolster. 5. Connect the negative battery cable(s). 6. Reprogram the BCM. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations Electronic Throttle Control Module: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 854 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 855 Electronic Throttle Control Module: Diagrams Throttle Actuator Control (TAC) Module Connector C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 856 Throttle Actuator Control (TAC) Module Connector C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 857 Electronic Throttle Control Module: Description and Operation THROTTLE ACTUATOR CONTROL (TAC) MODULE Throttle Actuator Control (TAC) Module The TAC module is the control center for the electronic throttle system. The TAC module and the powertrain control module (PCM) communicate via a dedicated redundant serial data circuit. The TAC module and the PCM monitor the commanded throttle position and compare the commanded position to the actual throttle position. This is accomplished by monitoring the APP and the TP sensor. These 2 values must be within a calibrated value of each other. The TAC module also monitors each individual circuit of the TP sensor and the APP to verify proper operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 858 Electronic Throttle Control Module: Service and Repair THROTTLE ACTUATOR CONTROL (TAC) MODULE REPLACEMENT REMOVAL PROCEDURE 1. Release the retainer tab from the left side of the throttle actuator control (TAC) module. 2. Slowly slide the TAC module out of the retaining bracket. 3. Disconnect the TAC module connectors from the TAC module. INSTALLATION PROCEDURE 1. Connect the TAC module connectors to the TAC module. 2. Slide the TAC module into the TAC module bracket. 3. Push the TAC module towards the bracket in order to snap the TAC module into the bracket. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 867 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 873 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 878 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 884 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 885 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 888 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 889 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 890 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 891 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 892 Engine Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 893 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 894 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 895 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 896 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 897 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 898 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 899 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 900 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 901 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 902 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 903 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 904 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 905 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 906 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 907 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 908 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 909 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 910 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 911 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 912 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 913 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 914 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 915 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 916 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 917 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 918 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 919 Powertrain Control Module (PCM) C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 920 Powertrain Control Module (PCM) C1 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 921 Powertrain Control Module (PCM) C2 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 922 Powertrain Control Module (PCM) C2 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 923 Powertrain Control Module (PCM) C2 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description Engine Control Module: Description and Operation Electronic Ignition (EI) System Description POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: ^ The Throttle Position (TP) Sensor ^ The Engine Coolant Temperature (ECT) Sensor ^ The Mass Airflow (MAF) sensor ^ The Intake Air Temperature (IAT) Sensor ^ The Vehicle Speed Sensor (VSS) ^ The transmission gear position or range information sensors ^ The Engine Knock Sensors (KS) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 926 Engine Control Module: Description and Operation Powertrain Control Module (PCM) Description General Information The Powertrain Control Module (PCM) is designed to maintain exhaust emission levels while maintaining excellent driveability and fuel efficiency. The PCM controls the following operations: ^ The fuel control ^ The Ignition Control (IC) ^ The Knock Sensor (KS) system ^ The automatic transmission shift functions ^ The manual transmission ^ The cruise control enable, if equipped ^ The generator ^ The evaporative emissions (EVAP) purge ^ The A/C clutch control, if equipped ^ The secondary air injection (AIR), if equipped ^ The Exhaust Gas Recirculation (EGR) PCM Function The PCM supplies a buffered voltage to various sensors and switches. The PCM controls most components with electronic switches which complete a ground circuit when turned ON. Powertrain Control Module Powertrain Control Module The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is the control center of the vehicle. The PCM controls the following: ^ The fuel metering system ^ The transmission shifting ^ The ignition timing ^ The on-board diagnostics for powertrain functions The PCM constantly monitors the information from various sensors and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic functions for those systems. The PCM can recognize operational problems and alert the driver through the Malfunction Indicator Lamp (MIL) when a malfunction has occurred. When a malfunction is detected, the PCM stores a Diagnostic Trouble Code (DTC) which helps to identify problem areas. This is done to aid the technician in making repairs. The PCM supplies either 5.0 or 12.0 volts to power various sensors and switches. This is done through resistances in the PCM. The resistance is so high in value that a test lamp does not illuminate when connected to the circuit. In some cases, even an ordinary shop voltmeter does not give an accurate reading because the voltmeters resistance is too low. Therefore, a DMM with a minimum of 10 megaohms input impedance is required to ensure accurate voltage readings. The PCM controls output circuits such as the fuel injectors, the Idle Air Control (IAC), the cooling fan relays, etc. by controlling the ground or the power feed circuit through transistors or a device called an output driver module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 927 Torque Management Torque management is a function of the PCM that reduces engine power under certain conditions. Torque management is performed for the following reasons: 1. To prevent over-stressing the powertrain and driveline components 2. To prevent damage to the vehicle during certain abusive maneuvers 3. To reduce engine speed when the IAC is out of the normal operating range The PCM monitors the following sensors and engine parameters in order to calculate engine output torque: ^ The air/fuel ratio ^ The Mass Air Flow (MAF) sensor ^ The Manifold Absolute Pressure (MAP) Sensor ^ The Intake Air Temperature (IAT) Sensor ^ The spark advance ^ The engine speed ^ The Engine Coolant Temperature (ECT) Sensor ^ The A/C clutch status The PCM monitors the torque converter status, the transmission gear ratio, and the engine speed in order to determine if torque reduction is required. The PCM retards the spark as appropriate to reduce engine torque output if torque reduction is required. The PCM also shuts OFF the fuel to certain injectors in order to reduce the engine power in the case of an abusive maneuver. The following are instances when engine power reduction is likely to be experienced: ^ During transmission upshifts and downshifts ^ During heavy acceleration from a standing start ^ When the clutch pedal is released too quick under a heavy load, 6.0L only ^ When one set of drive axles looses traction while the other set of drive axles are not moving, 4 Wheel Drive only and in 4WD low ^ If the IAC is out of the normal operating range, except 6.0L ^ When the driver is performing harsh or abusive maneuvers such as shifting into gear at high throttle angles or shifting the transmission from reverse to drive to create a rocking motion The driver is unlikely to notice the torque management actions in the first 2 instances. The engine power output is moderate at full throttle in the other cases. The PCM calculates the amount of spark retard necessary to reduce the engine power by the desired amount. The PCM disables the fuel injectors for cylinders 1, 4, 6, and 7 in the case of an abusive maneuver. Basic Knowledge Required Without a basic knowledge of electricity, you will have difficulty using the diagnostic procedures. You should understand the basic theory of electricity and know the meaning of voltage-volts, current-amps, and resistance-ohms. You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. PCM Service Precautions The PCM is designed to withstand normal current draws associated with vehicle operations. Avoid overloading any circuit. When testing for opens or shorts, do not ground any of the PCM circuits unless instructed. When testing for opens or shorts, do not apply voltage to any of the PCM circuits unless instructed. Only test these circuits with a DMM while the PCM connectors remain connected. Engine Controls Information The driveability and emissions information describes the function and operation of the powertrain control module (PCM). The engine controls Information contains the following: ^ Component locations ^ Wiring diagrams ^ PCM terminal end view and terminal definitions ^ Diagnostic System Check-Computers and Controls Systems ^ Diagnostic trouble code (DTC) tables The component system includes the following items: ^ Component and circuit description ^ On-vehicle service for each sub-system ^ Functional checks and diagnostic tables The DTCs also contain diagnostic support information containing circuit diagrams, circuit or system information, and helpful diagnostic information. System Status and Drive Cycle For Inspection/Maintenance The System Status selection is included in the scan tool System Info menu. Several states require that the I/M (OBD II system) pass on-board tests for the major diagnostics prior to having a vehicle emission inspection. This is Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 928 also a requirement to renew license plates in some areas. Using a scan tool, the technician can observe the System Status, complete or not complete, in order to verify that the vehicle meets the criteria to comply with local area requirements. Using the System Status display, any of the following systems or combination of systems may be monitored for I/M Readiness: ^ The catalyst ^ The Evaporative Emission (EVAP) system ^ The Heated Oxygen Sensors (HO2S) ^ The HO2S heater ^ The Exhaust Gas Recirculation (EGR) system ^ The secondary air injection (AIR) system IMPORTANT: The System Status display indicates only whether or not the test has been completed. The System Status display does not necessarily mean that the test has passed. If a Failed Last Test indication is present for a DTC associated with one of the above systems, diagnosis and repair is necessary in order to meet the I/M requirement. Verify that the vehicle passes all of the diagnostic tests associated with the displayed System Status prior to returning the vehicle to the customer. Refer to the Typical Drive Cycle table, more than one drive cycle may be needed, to use as a guide to complete the I/M System Status tests. Typical Drive Cycle Following a DTC info clear, System Status clears for one or all of these systems. Following a battery disconnect or a PCM replacement, all System Status information clears. Primary System Based Diagnostics There are primary system-based diagnostics which evaluate the system operation and their effect on vehicle emissions. The primary system-based diagnostics are listed below, with a brief description of the diagnostic functionality. Oxygen Sensor Diagnosis Diagnose the fuel control heated oxygen sensors (HO2S) for the following conditions: ^ Heater performance, heater current monitor ^ Response switches, number or switches R/L or L/R ^ Response time, time to switch R/L or L/R ^ Inactive signal, output steady at bias voltage - approximately 450 mV ^ Signal fixed high ^ Signal fixed low Diagnose the catalyst monitor HO2S for the following functions: ^ Heater performance, heater current monitor ^ Signal fixed low ^ Signal fixed high ^ Inactive sensor Heated Oxygen Sensors The main function of the pre-catalyst HO2S is to provide the PCM with exhaust stream information in order to maintain proper fueling to hold emissions within acceptable levels. These oxygen sensors are always located between the exhaust manifold and the 3-way Catalytic Converter (TWC). After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases. The PCM uses the signal voltage from the fuel control HO2S in a Closed Loop in order to adjust the fuel injector pulse width. While in a Closed Loop, the PCM can adjust fuel delivery in order to maintain an air to fuel ratio which allows the best combination of emission control and driveability. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 929 If the HO2S pigtail wiring, connector, or terminal are damaged, replace the entire HO2S assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must be provided with a clean air reference. This clean air reference is obtained by way of the HO2S wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference. Any attempt to repair the wires, connectors, or terminals could degrade HO2S performance. Catalyst Monitor Heated Oxygen Sensors In order to control emissions of HydroCarbons (HC), Carbon Monoxide (CO), and Oxides Of Nitrogen (NOx), the system uses a TWC. The catalyst promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting the HC and CO into harmless water vapor and carbon dioxide. The catalyst also converts NOx to nitrogen. Catalyst monitor HO2S, post-catalyst HO2S, are always located downstream of the catalytic converter. The PCM has the ability to monitor this process using the post catalyst HO2S. The pre-sensors produce an output signal which indicates the amount of oxygen present in the exhaust gas entering the TWC. The post sensor produces an output signal which indicates the oxygen storage capacity of the catalyst. This in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the pre-HO2S signal is far more active than that produced by the post-HO2S. In addition to catalyst monitoring, the post-HO2S has a limited role in controlling fuel delivery. If the post-HO2S signal indicates a high or low oxygen content for an extended period of time while in a Closed Loop, the PCM adjusts the fuel delivery slightly in order to compensate. Catalyst Monitor Diagnostic Operation The catalyst monitor diagnostic measures oxygen storage capacity of the catalyst converter. In order to do this, the HO2S are installed before and after the TWC. Voltage variations between the sensors allow the PCM to determine the catalyst emission performance. As a catalyst becomes less effective in promoting chemical reactions, the catalysts capacity to store and release oxygen generally degrades. The catalyst monitor diagnostic is based on a correlation between conversion efficiency and oxygen storage capacity. A good catalyst, e.g. 95 percent hydrocarbon conversion efficiency, shows a relatively flat output voltage on the post-catalyst HO2S. A degraded catalyst, 65 percent hydrocarbon conversion, shows a greatly increased activity in output voltage from the post catalyst HO2S. The post-catalyst HO2S is used to measure the oxygen storage and release capacity of the catalyst. A high oxygen storage capacity indicates a good catalyst. Low oxygen storage capacity indicates a failing catalyst. The TWC and the HO2S must be at operating temperature in order to achieve correct oxygen sensor voltages like those shown in the post-catalyst HO2S outputs graphic. The catalyst monitor diagnostic is sensitive to the following conditions: ^ Exhaust leaks ^ HO2S contamination ^ Alternative fuels Exhaust system leaks may cause the following: ^ Prevent a degraded catalyst from failing the diagnostic ^ Cause a false failure for a normally functioning catalyst ^ Prevent the diagnostic from running Some of the contaminants that may be encountered are phosphorus, lead, silica, and sulfur. The presence of these contaminants prevent the TWC diagnostic from functioning properly. Three-Way Catalyst Oxygen Storage Capacity Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 930 Three-Way Catalyst Oxygen Storage Capacity The PCM must monitor the TWC system for efficiency. In order to accomplish this, the PCM monitors the pre-catalyst and post-catalyst HO2S. When the TWC is operating properly, the post-catalyst (2) HO2S shows significantly less activity than the pre-catalyst (1) HO2S. The TWC stores oxygen during the normal reduction and oxidation process. The TWC releases oxygen during the normal reduction and oxidation process. The PCM calculates the oxygen storage capacity using the difference between the pre-catalyst and post-catalyst HO2S voltage levels. Whenever the sensor activity of the post-catalyst (2) HO2S nears the sensor activity of the pre-catalyst (1) HO2S, the catalysts efficiency is degraded. Aftermarket HO2S characteristics may be different from the original equipment manufacturer sensor. This may lead to a false pass or a false fail of the catalyst monitor diagnostic. Similarly, if an aftermarket catalyst does not contain the same amount of precious metal content as the original part, the correlation between oxygen storage and conversion efficiency may be altered enough to set a false DTC. Misfire Monitor Diagnostic Operation The misfire monitor diagnostic is based on crankshaft rotational velocity, aka reference period, variations. The PCM determines crankshaft rotational velocity using the Crankshaft Position (CKP) Sensor and Camshaft Position (CMP) Sensor. When a cylinder misfires, the crankshaft slows down momentarily. By monitoring the crankshaft and CMP sensor signals, the PCM can calculate when a misfire occurs. For a non-catalyst damaging misfire, the diagnostic is required to monitor a misfire present for between 1,000-3,200 engine revolutions. For catalyst damage misfire, the diagnostic responds to the misfire within 200 engine revolutions Rough roads may cause false misfire detection. A rough road applies sudden torque variations to the drive wheels and drivetrain. This torque can intermittently decrease the crankshaft rotational velocity. The Antilock Braking (ABS) System detects uneven speed between the vehicles wheels and sends data via the serial data bus to the PCM to disable the misfire monitor until the rough road is no longer detected. On automatic transmission equipped vehicles, the Torque Converter Clutch (TCC) disables whenever a misfire is detected. Disabling the TCC isolates the engine from the rest of the drive line and minimizes the affect of the drive wheel inputs on crankshaft rotation. When the TCC has disabled as a result of misfire detection, the TCC is re-enabled after approximately 3,200 engine revolutions if no misfire is detected. The TCC remains disabled whenever the misfire is detected, with or without a DTC set. This allows the misfire diagnostic to reevaluate the system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 931 Whenever a cylinder misfires, the misfire diagnostic counts the misfire and notes the crankshaft position at the time the misfire occurred. A current and a history misfire counter is maintained for each cylinder. The misfire current counters, Misfire Cur #1-8, indicate the number of firing events out of the last 200 cylinder firing events which were misfires. The misfire current counters displays real time data without a misfire DTC stored. The misfire history counters, Misfire Hist #1-8, indicate the total number of cylinder firing events which were misfires. The misfire history counters display 0 until the misfire diagnostic has failed and a DTC P0300 is set. Once the misfire DTC sets, the misfire history counters will be updated every 200 cylinder firing events. The Misfire counters graphic illustrates how these misfire counters are maintained. When crankshaft rotation is erratic, the PCM detects a misfire condition. Because of this erratic condition, the data that is collected by the diagnostic can sometimes incorrectly identify which cylinder is misfiring. The Misfire Counters graphic shows there are misfires counted from more than one cylinder. Cylinder #1 has the majority of counted misfires. In this case, the misfire counters would identify cylinder #1 as the misfiring cylinder. The misfires in the other counters were just background noise caused by the erratic rotation of the crankshaft. If the number of accumulated misfires is sufficient for the diagnostic to identify a true misfire, the diagnostic will set DTC P0300-Misfire Detected. The illustration depicts an accumulation in the history buffers. If two cylinders in sequential tiring order are both misfiring, the first misfiring cylinder will accumulate misfires in the cylinder buffer, but the second misfiring cylinder will not. This is because the PCM compares a misfiring cylinder with the cylinder 90 degrees prior to that cylinder in the firing order. Therefore the PCM would be comparing crankshaft speed of the second misfiring cylinder to an already suspect cylinder. The PCM however, will be able to detect both misfiring cylinders after the engine exceeds 2,000 RPM. This is because the PCM then starts to compare misfires to the opposing cylinder rather than the previous cylinder in the firing order. Use Techline equipment to monitor the misfire counter data on applicable vehicles. Knowing which specific cylinders misfire can lead to the root cause. Using the information in the misfire counters identifies which cylinders are misfiring. If the counters indicate cylinders number 1 and 4 misfired, look for a circuit or component common to both cylinders. The misfire diagnostic may indicate a fault due to a temporary fault not necessarily caused by a vehicle emission system malfunction. Examples include the following items: ^ Contaminated fuel Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 932 ^ Running out of fuel ^ Fuel fouled spark plugs ^ Basic engine fault Fuel Trim System Operation The fuel trim system monitors the averages of short-term and long-term fuel trim values. If these fuel trim values stay at the individual limits for a calibrated period of time, a malfunction is indicated. The fuel trim diagnostic compares the average of short and long-term fuel trim values. If either value is within the thresholds, a pass is recorded. If either value is outside the thresholds, a rich or lean fuel trim DTC will set. Comprehensive Component Monitor Diagnostic Comprehensive component monitoring diagnostics are required to monitor emissions-related input and output powertrain components. Input Components The PCM monitors the input components for circuit continuity and out-of-range values. This includes performance checking. Performance checking refers to indicating a fault when the signal from a sensor does not seem reasonable, such as a Throttle Position (TP) sensor that indicates high throttle position at low engine loads or manifold Absolute Pressure (MAP) Voltage. The input components may include, but are not limited to, the following sensors: ^ The Vehicle Speed (VSS) Sensor ^ The Mass Air Flow (MAF) Sensor ^ The Intake Air Temperature (IAT) Sensor ^ The Crankshaft Position (CKP) Sensor ^ The Knock Sensor (KS) ^ The Throttle Position (TP) Sensor ^ The Engine Coolant Temperature (ECT) Sensor ^ The Camshaft Position (CMP) Sensor ^ The Manifold Absolute Pressure (MAP) Sensor In addition to the circuit continuity and rationality check, the engine coolant temperature (ECT) sensor is monitored for the sensors ability to achieve a steady state temperature to enable Closed Loop fuel control. Output Components Diagnose the output components for the proper response to PCM commands. Components where functional monitoring is not feasible will be monitored for circuit continuity and out-of-range values if applicable. Output components to be monitored include, but are not limited to, the following circuits: ^ The Idle Air Control (IAC) Motor ^ The Evaporative Emission (EVAP) System ^ The electronic transmission controls ^ The A/C relay, if equipped ^ The VSS output ^ The Malfunction Indicator Lamp (MIL) Control ^ The cruise control enable, if equipped Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) Engine Control Module: Service and Repair Powertrain Control Module (PCM) Programming (Off-board) BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: ^ DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. ^ The Off-Board Programming is used in situations where a control module must be programmed without having the vehicle present. The Off-Board Programming Adapter must be used to perform the Off-Board Programming procedure. The adapter allows the control module to power up and allows the Tech 2 to communicate with the control module. ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. Ensure that all connections are secure at the following locations: ^ The Off-Board Programming Adapter ^ The Tech 2 ^ The control module ^ The Techline terminal OFF-BOARD PROGRAMMING 1. Obtain the VIN of the vehicle for which the control module is being programmed. 2. With the Techline terminal, select Service Programming. 3. Select Tech 2, Reprogram ECU, and Off-Board Programming Adapter as the ECU location. 4. Connect the control module, Off-Board Programming Adapter, and the Tech 2 as described on the Techline terminal. Ensure you use the correct harness connector from the Off-Board Programming Adapter kit. 5. With the Tech 2, select Service Programming Request Information function. The Tech 2 communicates with the control module and receives the access code. 6. With the Tech 2, exit the Service Programming Request Information. 7. Disconnect the Tech 2 from the Off-Board Programming Adapter. 8. Connect the Tech 2 to the Techline terminal. 9. Turn ON the Tech 2. 10. With the Techline terminal, enter the VIN of the vehicle that will be receiving the control module. 11. The Techline terminal will display the message, attaching to database. 12. Identify what type of programming that you are performing. 13. Select the appropriate calibration file. 14. Ensure all connections are secure. 15. The Techline terminal displays a summary screen that summarizes your selections. After confirming you choices, the Techline terminal automatically loads the calibration files to the Tech 2. 16. After the download is complete, turn OFF the Tech 2. 17. Disconnect the Tech 2 from the Techline terminal. 18. Connect the Tech 2 to the Off-Board Programming Adapter. 19. With the Tech 2, select Service Programming. IMPORTANT: DO NOT turn OFF the Off-Board Programming Adapter if the programming procedure is interrupted or unsuccessful. Ensure the control module and the Off-Board Programming Adapter connections are secure and the Techline operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. 20. With the Tech 2, select Program. 21. After the download is complete, exit Service Programming. 22. Turn OFF the Off-Board Programming Adapter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 935 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Programming (On-Board) BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customers concern. Ensure the following conditions are met before programming a control module: ^ Vehicle system voltage There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicle's battery. ^ Twilight sentinel ^ Interior lights ^ Daytime running lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. Refer to the Owners manual. ^ HVAC systems ^ Cooling System fans, etc. ^ The ignition is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. ^ All tool connections are secure. RS-232 - The connection at the DLC is secure. - Voltage supply circuits ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. REMOTE PROGRAMMING 1. Turn OFF the ignition. 2. Install the Tech 2 to the data link connector (DLC). 3. Turn ON the ignition, with the engine OFF. 4. Turn OFF all vehicle accessories. 5. With the Tech 2, select Service Programming. 6. Identify vehicle information as requested by the Tech 2. 7. Select the type of module you are programming. 8. Select the type of programming to be performed. 9. Verify the displayed VIN with the vehicle VIN. If the displayed VIN does not match the actual VIN, write down the actual VIN and correct the VIN at the Techline terminal. 10. When complete, Exit Service Programming. 11. Turn OFF the Tech 2 and disconnect the Tech 2 from the vehicle. 12. Turn OFF the ignition. 13. Connect the Tech 2 to the Techline terminal. 14. Select Service Programming. 15. Select Tech 2 as the tool you are using. 16. Select the type of programming to be performed. 17. Verify the displayed VIN with the vehicle VIN. Correct the VIN as necessary. 18. Select the type of module you are programming. 19. Identify what type of programming that you are performing. ^ Normal-This type of programming is for updating an existing calibration or programming a new controller. ^ Vehicle configuration index (VCI)-This selection is used if the vehicle VIN is unavailable or not recognized by the Techline terminal. Observe, you will need to contact the Techline Customer Support center to use this option. ^ Reconfigure-This is to reconfigure a vehicle, such as tire size and axle ratio changes. 20. Select the appropriate calibration file. 21. Ensure all connections are secure. 22. Select Reprog to initiate the download of the new calibration to the Tech 2. 23. After the download is complete, turn OFF the Tech 2. 24. Disconnect the Tech 2 from the Techline terminal. 25. Install the Tech 2 to the data link connector (DLC). 26. Turn ON the Tech 2. 27. Turn ON the ignition, with the engine OFF. 28. Select Service Programming. IMPORTANT: DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all the PCM and DLC Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 936 connections are secure and the Techline(TM) operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. Refer to Powertrain Control Module (PCM) Replacement. 29. Select Program. 30. After the download is complete, EXIT Service Programming. 31. Turn OFF the ignition for 30 seconds. 32. Turn OFF the Tech 2. 33. If a control module is replaced the following service procedures must be performed: ^ CKP System Variation Learn Procedure ^ Inspection/Maintenance (I/M) Complete System Set Procedure ^ Programming Theft Deterrent System Components PROGRAMMING VERIFICATION 1. With a scan tool, clear the DTCs. 2. Attempt to start the engine. 3. Repeat the Service Programming procedure if the engine does not start or operates poorly. Perform the following procedures before programming the PCM: ^ Ensure the control module and DLC connections are OK. ^ Ensure the Techline operating software is up to date. ^ Ensure the calibration part number is correct for the vehicle. 4. Attempt to program the control module. If the control module still cannot be programmed properly, replace the control module. Refer to Powertrain Control Module (PCM) Replacement. You must program the replacement control module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 937 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Replacement Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. ^ Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. ^ The replacement PCM must be programmed Removal Procedure 1. Release the PCM cover mounting holes (1,5) away from the mounting tabs on the PCM mounting bracket. 2. Release the PCM cover (8) from the mounting bracket. 3. Remove the PCM cover. NOTE: ^ Refer to PCM and ESD Notice in Service Precautions. ^ In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 4. Disconnect the PCM harness connectors (6). 5. Release the spring latch (2) from the PCM. 6. Release the PCM mounting tabs (3) from the PCM. 7. Remove the PCM (4) from the engine compartment. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 938 1. Install the PCM (4) to the PCM mounting bracket (7) ensuring that the mounting tabs (3) are engaged. 2. Secure the spring latch (2) to the PCM. NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the PCM connectors (6) to the PCM (4). Tighten Tighten the PCM connector end fasteners to 8 N.m (71 lb in). 4. Install the PCM cover (8) to the PCM mounting bracket (7), ensuring the mounting tabs on the PCM mounting bracket are engaged into the mounting holes in the PCM cover. 5. If a new PCM is being installed, program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 939 Engine Control Module: Service and Repair Service Programming System (SPS) The Service Programming System (SPS) allows a technician to program a control module through the Data Link Connector (DLC). The information transfer circuit that is used at the DLC is the same serial data circuit used by the scan tool for retrieving Diagnostic Trouble Codes (DTCs), displaying data, clearing DTCs, etc. This procedure offers the ability to install software/calibrations matched to a particular vehicle. Most control modules have 2 types of memory. The software/calibrations reside in the flash memory. The two types of memory are listed below: ^ Electrically Erasable Programmable Read Only Memory (EEPROM) This type of memory allows selected portions of memory to be programmed while other portions remain unchanged. Certain learned values reside in the EEPROM, such as: ^ The Vehicle Identification Number (VIN) ^ The crankshaft variation learned position ^ The software/calibrations identification numbers ^ The control module security information ^ Flash Read Only Memory - Flash Memory ^ Flash memory has increased memory storage capacity. During programming, all information within this type of memory is erased, and then replaced with entirely new information. Service Programming Methods The 4 methods of programming a control module and the proper tools for each method are as follows: ^ Remote Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle ^ Pass Thru Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle. ^ Off-Board Remote Programming, vehicle NOT available: The Tech 2 or other scan tool, Off-board Programming Adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle ^ Off-Board Pass Thru Programming - The Tech 2 or other scan tool, off-board programming adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle Before Programming A Control Module IMPORTANT: DO NOT program an existing control module with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A control module should only be programmed when the following occurs: ^ When a service procedure instructs you to replace the control module. The service part control module does not contain operating software or calibrations. ^ General Motors Corporation releases an updated software/calibration package. Ensure that the following conditions are met before programming a control module: ^ Vehicle system voltage: There are no charging system concerns. All charging system concerns must be repaired before programming a control module. - The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged before programming the control module. - A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or disable systems such as: ^ Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. ^ Heating, Ventilation, And Air Conditioning (HVAC) systems ^ Engine cooling fans, etc ^ The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. ^ All tool connections are secure: The RS-232 cable - The connection at the DLC - The voltage supply circuits Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 940 - The OBPA ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. ^ If you are performing the pass-through programming procedure using a notebook computer without the power cord, ensure that the internal battery is fully charged. After Programming a Control Module The powertrain may operate slightly different after a control module software/calibration update. Operating the powertrain through various driving conditions allows the control module to re-learn certain values. The control module must re-learn the following after a software/calibration update: ^ Fuel trim correction ^ Idle Air Control (IAC) learned position ^ Automatic transmission shift adapts Other learned values only re-learn by performing a service procedure. If a control module is replaced the following service procedures may need to be performed: ^ The crankshaft variation learn procedure ^ The engine oil life reset procedure ^ The idle learn procedure ^ The inspection/maintenance complete system set procedure ^ The vehicle theft deterrent password learn procedure ^ The Throttle Position (TP) sensor learn procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay Fuel Pump Relay: Locations Fuel Pump Relay FUEL PUMP RELAY Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 946 Locations View The Fuel Pump (FP) Relay is located in the Underhood Fuse Block. The Underhood Fuse Block is located at the left side of the engine compartment near the battery. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 947 Fuel Pump Relay: Locations Fuel Pump Relay Secondary - With Dual Tanks SECONDARY FUEL PUMP RELAY (With Dual Tanks Only) Locations View The Secondary Fuel Pump (FP) Relay (1) is attached to the Underhood Fuse Block on bracket. The Underhood Fuse Block is located at the left side of the engine compartment near the battery. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 948 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 951 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 952 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 953 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 954 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 955 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 956 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 957 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 958 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 959 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 960 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 961 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 962 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 963 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 964 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 965 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 966 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 967 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 968 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 969 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 970 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 971 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 972 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 973 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 974 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 975 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 976 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 977 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 978 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 979 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 980 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 981 Fuel Pump (FP) Relay-Secondary Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ignition Relay: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 986 Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 987 Ignition Relay: Testing and Inspection CIRCUIT DESCRIPTION The ignition relay supplies battery positive voltage to the following components: ^ The fuel injectors ^ The ignition coils ^ The powertrain control module (PCM) ^ The throttle actuator control (TAC) module DIAGNOSTIC AIDS The following will occur if the ignition relay fails to close: ^ The engine cranks, but does not run. ^ Scan tool data will be available. ^ Instrument panel lights will illuminate. TEST DESCRIPTION Steps 1-5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 988 Steps 6-11 The numbers below refer to the step numbers on the diagnostic table. 2. This step is testing the battery positive voltage circuit of the ignition relay. 3. This step is testing the ignition 1 positive voltage circuit of the ignition relay. 4. This step is testing the coil ground circuit of the ignition relay. 5. This step isolates the circuits from the ignition relay. All of the circuits at the relay are good if the test lamp illuminates. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 993 Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 994 Starter Relay: Service and Repair REMOVAL PROCEDURE 1. Remove the underhood bussed electrical center (UBEC) cover. 2. Remove the starter motor relay. INSTALLATION PROCEDURE 1. Install the starter motor relay. 2. Install the underhood bussed electrical center (UBEC) cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Electronic Suspension Control Module to Bracket .............................................................................................................................. 1.6 Nm (14 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > C1 > Page 1002 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > C1 > Page 1003 Suspension Control Module: Diagrams C3 Suspension Control Module - C3 Part 1 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > C1 > Page 1004 Part 2 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > Page 1005 Suspension Control Module: Service and Repair Electronic Suspension Control Module Replacement (Tahoe/Yukon/Escalade) Removal Procedure 1. Remove the right side interior trim panel. 2. Disconnect the electrical connectors from the module. 3. Remove the screw. 4. Slide the module from the bracket and remove the module from the vehicle. Installation Procedure 1. Install the module to the vehicle by sliding the module into the bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screw. Tighten the screw to 1.6 Nm (14 inch lbs.). 3. Connect the electrical connectors to the module. 4. If you are replacing the module you must recalibrate the module by performing the following procedure: ^ Connect the scan tool to the Data Line Connector (DLC). ^ Turn the ignition ON with the engine OFF. ^ Proceed per the instructions on the scan tool readout. 5. Install the right side interior trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 1017 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 Control Module: Diagrams Transfer Case Shift Control Module - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 > Page 1020 Transfer Case Shift Control Module - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 > Page 1021 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 1022 Control Module: Service and Repair Transfer Case Shift Control Module Replacement Removal Procedure 1. Remove the IP trim bezel. 2. Pull out the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly in order to disconnect the electrical connectors. 3. Disconnect all the electrical connectors from the lamp switch, cargo lamp and 4WD shift buttons assembly. 4. Remove the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly from the vehicle. 5. Remove the electrical harness retainer from the IP support beam. 6. Disconnect the 2 electrical connectors from the transfer case shift control module. 7. Move the electrical harness to the left side in order to make room to turn the transfer case shift control module. 8. Rotate the transfer case shift control module about 45 degrees counter clockwise while pulling out at the same time until the module is Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 1023 approximately 90 degrees from the original position. 9. Pull out the module from the vehicle. Installation Procedure 1. Move the electrical harness to the left side in order to make room to install the transfer case shift control module. 2. Install the transfer case shift control module so that the electrical connector ports are to the right or pointing towards the instrument cluster. 3. While installing the transfer case shift control module rotate clockwise until the module is in place and the electrical connector ports are facing outwards. 4. Install the electrical harness retainer to the IP support beam. 5. Connect the 2 electrical connectors to the transfer case shift control module. 6. Install the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly the vehicle. 7. Connect all the electrical connectors to the lamp switch, cargo lamp and 4WD shift buttons assembly. 8. Install the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly in place. 9. Install the IP trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 1024 10. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 1032 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Service and Repair > Module Replacement - Rear Power Window Power Window Control Module: Service and Repair Module Replacement - Rear Power Window REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the water deflector. 3. Remove the window glass. 4. Remove the window sash. 5. Remove the glass weatherstrip. 6. Remove the module from the door. INSTALLATION PROCEDURE 1. Install the module to the door. 2. Install the glass weatherstrip. 3. Install the window sash. 4. Install the window glass. 5. Install the water deflector. 6. Install the trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Service and Repair > Module Replacement - Rear Power Window > Page 1037 Power Window Control Module: Service and Repair Module Replacement - Front Power Window REMOVAL PROCEDURE 1. Raise and support the window glass. 2. Remove the trim panel. 3. Remove the water deflector. 4. Disconnect the harness from the electric window motor assembly. 5. Remove the 2 bolts that hold the window glass to the regulator. 6. Remove the bolts from the window regulator. 7. Remove the window regulator assembly from the door by folding both sides of the window regulator assembly together. INSTALLATION PROCEDURE 1. Install the regulator to the door. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the window regulator. Tighten Tighten the bolts to 9 N.m (80 lb in). 3. Align the window glass to the regulator, and install the bolts that hold the window glass to the regulator. Tighten Tighten the bolts to 9 N.m (80 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Service and Repair > Module Replacement - Rear Power Window > Page 1038 4. Connect the harness to the electric window motor assembly. 5. Install the water deflector. 6. Install the trim panel. 7. Lower the window. Inspect the operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams Passlock Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams Parking Assist Distance Sensor: Diagrams Object Sensor - LR Corner Object Sensor - RR Corner Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 1047 Object Sensor - LR Middle Object Sensor - RR Middle Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 1048 Parking Assist Distance Sensor: Service and Repair REAR OBJECT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connectors to the rear object sensor. 2. Lift the locking tabs on the housing (4) and remove the rear object sensor (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 1049 3. Insert a small size screw driver at (3) to release the tabs in order to remove the spring (1). 4. From the inside of the housing push in the tabs and remove. 5. Remove the bezel by pushing it through the fascia. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 1050 IMPORTANT: Do not paint the sensor. 1. Paint the sensor bezel to match the color of the bumper fascia. 2. Align the keyhole (2) with the key (1) and press the sensor bezel into the fascia. 3. Install the housing to the bezel through the back side of the fascia. The housing snaps into the cutouts on the bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 1051 IMPORTANT: The spring keys must be on the top and bottom of the housing. 4. Install the spring (1) to the housing (2) until fully seated. Ensure the sensor is held to the bumper fascia firmly. 5. Install the decoupling ring (2) to the sensor (1). 6. Insert the sensor into the housing (4) with the connector pointing toward the passenger side of the fascia. The sensor tabs snap into the cutouts on the housing (4). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 1052 7. Connect the electrical connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations > Page 1056 Rear Parking Assist (RPA) Disable Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations > Page 1057 Parking Assist Switch: Service and Repair REAR OBJECT ALARM MODULE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the dash trim bezel. 2. Grasp the buttons assembly (2) housing and pull outwards. 3. Disconnect the electrical connector from the rear object alarm module switch. 4. Remove the switch (1) from the housing (2). INSTALLATION PROCEDURE 1. Install the rear object alarm switch into the housing (2). 2. Connect the electrical connector to the switch (1). 3. Install the switch housing into the dash. 4. Install the dash trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Underhood Lamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1068 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1069 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1070 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1071 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1072 Underhood Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1073 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1074 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1075 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1076 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1077 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1078 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1079 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1080 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1081 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1082 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1083 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1084 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1085 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1086 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1087 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1088 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1089 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1090 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1091 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1092 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1093 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1094 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1095 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1096 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1097 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch - Driver/Front Passenger Door Lock Switch - Driver/Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch - Driver/Front Passenger > Page 1102 Window/Door Lock Switch - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Door Lock Switch Replacement - Front Power Door Lock Switch: Service and Repair Power Door Lock Switch Replacement - Front REMOVAL PROCEDURE 1. Remove the power accessory switch panel. 2. Disconnect the electrical connector from the door lock switch. 3. Remove the screws from the door lock switch. 4. Remove the power window and door lock switch from the switch panel. INSTALLATION PROCEDURE 1. Install the power door lock and power window switch assembly to the switch panel, sliding the front tabs in first. Rock the switch down in order to seat the door lock switch completely. 2. Install the screws to the door lock switch. 3. Connect the electrical connector to the door lock switch. 4. Install the power accessory switch plate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Door Lock Switch Replacement - Front > Page 1105 Power Door Lock Switch: Service and Repair Power Door Lock Switch Replacement - Rear REMOVAL PROCEDURE 1. Remove the upper garnish molding. 2. Remove the D-Pillar molding. 3. Disconnect the electrical connectors. 4. Push on the tab (2) in order to remove the switch from the D-Pillar molding. 5. Insert a small screwdriver between the tab (1) in order to pry out the switch from the case. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Door Lock Switch Replacement - Front > Page 1106 1. Install the switch into the case by pushing until the tab (1) locks into place. 2. Install the switch assembly into the D-Pillar molding. 3. Connect the electrical connectors. 4. Install the D-Pillar molding to vehicle. 5. Install the upper garnish molding to vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch Replacement Power Mirror Switch: Service and Repair Power Mirror Switch Replacement REMOVAL PROCEDURE 1. Remove the power accessory switch panel. 2. Remove the power mirror switch from the accessory switch panel using a flat-bladed tool in order to release the retainer tabs. INSTALLATION PROCEDURE 1. Install the power mirror switch, pressing the switch into place until fully seated. 2. Install the power accessory switch panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch Replacement > Page 1111 Power Mirror Switch: Service and Repair Power Folding Outside Mirror Switch Replacement REMOVAL PROCEDURE 1. Remove the instrument panel (IP) bezel. 2. Release the plastic retaining clips using a flat-bladed tool in order to remove the power folding mirror switch. 3. Disconnect the electrical connectors. 4. Remove the power folding mirror switch from the IP accessory housing. INSTALLATION PROCEDURE 1. Connect the electrical connectors. 2. Install the power folding mirror switch to the IP accessory housing. 3. Push in the power folding mirror switch until the switch snaps into position. 4. Install the power accessory switch panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Recliner Motor Position Sensor - Driver Seat Recliner Motor Position Sensor - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Recliner Motor Position Sensor - Driver > Page 1116 Seat Front Vertical Motor Position Sensor - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Recliner Motor Position Sensor - Driver > Page 1117 Seat Horizontal Motor Position Sensor - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Recliner Motor Position Sensor - Driver > Page 1118 Seat Rear Vertical Motor Position Sensor - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: Customer Interest Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing > Page 1127 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: All Technical Service Bulletins Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing > Page 1133 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch Power Seat Switch: Diagrams Lumbar/Bolster Switch Lumbar/Bolster Switch - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch > Page 1136 Lumbar/Bolster Switch - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch > Page 1137 Power Seat Switch: Diagrams Seat Adjuster Switch Seat Adjuster Switch - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch > Page 1138 Seat Adjuster Switch - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch > Page 1139 Seat Adjuster Switch - Driver - Full Feature Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch > Page 1140 Seat Adjuster Switch - Front Passenger - Full Feature Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Switch Bezel Replacement Power Seat Switch: Service and Repair Seat Switch Bezel Replacement Seat Switch Bezel Replacement Removal Procedure 1. Remove the lumbar knob, if equipped. 2. Remove the screws retaining the power seat switch bezel. 3. Disconnect the electrical connectors. 4. Remove the lumbar support switch. 5. Remove the power seat adjuster switch assembly. Installation Procedure 1. Install the power seat adjuster switch assembly to the seat switch bezel. 2. Install the lumbar support switch to the seat switch bezel. 3. Connect the electrical connectors. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the screws retaining the power seat switch bezel. Tighten the screws to 2 N.m (18 lb in). 5. Install the lumbar knob, if equipped. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Switch Bezel Replacement > Page 1143 Power Seat Switch: Service and Repair Seat Switch Replacement - Power Seat Switch Replacement - Power Removal Procedure 1. Remove the lumbar knob, if equipped. 2. Remove the power seat switch bezel from the seat. 3. Remove the power seat switch to bezel screws. 4. Remove the power seat switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten the screws to 2 N.m (18 lb in). 2. Install the power seat switch bezel to the seat. 3. Install the lumbar knob, if equipped. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Switch Bezel Replacement > Page 1144 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Removal Procedure 1. Remove the power seat switch bezel containing the lumbar switch (1) from the seat. 2. Remove the lumbar switch screws from the power seat switch bezel. 3. Remove the lumbar switch. Installation Procedure 1. Install the lumbar switch to the power seat switch bezel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the lumbar switch screws. Tighten the screws to 2 N.m (18 lb in). 3. Install the power seat switch bezel (1) to the seat. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams Liftgate/Liftglass Ajar Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 1151 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 1152 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 1153 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 1154 Seat Heater Switch: Diagrams Heated Seat Switch - Front Passenger Heated Seat Switch - LR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 1155 Heated Seat Switch - RR Memory/Heated Seat Switch - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Replacement - Front Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Front Heated Seat Switch Replacement - Front Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the retaining clips for the front seat heater switch in order to remove the switch. 4. Remove the front seat heater switch. Installation Procedure 1. Install the front seat heater switch to the front trim panel by pressing the switch into place until the switch is completely seated. 2. Connect the electrical connector to the front seat heater switch. 3. Install the front trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Replacement - Front > Page 1158 Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Rear Heated Seat Switch Replacement - Rear Removal Procedure 1. Remove the center console end panel. 2. Disconnect the electrical connector. 3. Remove the seat heater switch retaining screws. 4. Remove the switch from the vehicle. Installation Procedure 1. Install the switch to the console panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screw. Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector. 4. Install the center console end panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Sunroof Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 1162 Sunroof / Moonroof Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the roof console assembly. 2. Disconnect the electrical connector. 3. Remove the switch by un-snapping from roof console assembly. INSTALLATION PROCEDURE 1. Install the switch to roof console assembly by snapping into place. 2. Connect the electrical connector. 3. Install the roof console assembly. 4. Synchronize the sunroof motor. Refer to Sunroof Motor Synchronization. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Trunk / Liftgate Switch: Diagrams Cargo Door Ajar Switch Cargo Door Key Switch - Security - RH Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 1166 Liftgate Key Switch - Security Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 1171 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector from the fluid level sensor. 2. Remove the fluid level sensor (1). Use a needle nose pliers in order to compress the locking tabs at the opposite side of the master cylinder. Installation Procedure 1. Install the fluid level sensor (1) until the locking tabs snap into place. 2. Connect the electrical connector to the fluid level sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Specifications Brake Fluid Pressure Sensor/Switch: Specifications Brake Fluid Pressure Sensor (JL4) ........................................................................................................................................................... 16 Nm (12 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > MPA Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > MPA Switch > Page 1177 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Service and Repair > Brake Fluid Pressure Sensor Replacement Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Fluid Pressure Sensor Replacement Brake Fluid Pressure Sensor Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the alien bolt (2) from the Brake Pressure Modulator Valve (BPMV) mounting bracket (3) located on the sensor side. 3. Raise the BPMV to access the brake fluid pressure sensor. 4. Disconnect the electrical connector from the brake fluid pressure sensor. Important: The replacement of the old brake fluid pressure sensor must be performed quickly to reduce the amount of fluid that is lost during the procedure. 5. Use a wrench to keep the brake fluid pressure sensor collar from turning (1). Remove the brake fluid pressure sensor (2) from the BPMV. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Service and Repair > Brake Fluid Pressure Sensor Replacement > Page 1180 Notice: Refer to Fastener Notice in Service Precautions. 1. Quickly install the new brake fluid pressure sensor (2) to the BPMV as soon as the old sensor has been removed. Use a wrench to keep the brake fluid pressure sensor collar from turning (1). Tighten the brake fluid pressure sensor to 16 Nm (12 ft. lbs.). 2. Install the alien bolt (2) to the Brake Pressure Modulator Valve (BPMV) mounting bracket (3). Tighten the alien bolt to 9 Nm (7 ft. lbs.). 3. Connect the electrical connector to the brake fluid pressure sensor. 4. Lower the vehicle. 5. Check and fill the brake fluid level in the master cylinder. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Service and Repair > Brake Fluid Pressure Sensor Replacement > Page 1181 Brake Fluid Pressure Sensor/Switch: Service and Repair Pressure Accumulator Switch Replacement Pressure Accumulator Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the bolts (2) that secure the Brake Pressure Modulator Valve (BPMV) (1) to the mounting bracket (3). 3. Disconnect the electrical connector from the pressure accumulator switch. 4. Position the BPMV to be able to remove the pressure accumulator switch. 5. Remove the pressure accumulator switch from the BPMV. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Service and Repair > Brake Fluid Pressure Sensor Replacement > Page 1182 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the pressure accumulator switch to the BPMV. Tighten the pressure accumulator switch to 3 Nm (30 inch lbs.). 2. Connect the electrical connector to the pressure accumulator switch. 3. Install the Brake Pressure Modulator Valve (BPMV) (1) and the bolts (2) to the mounting bracket (3). Tighten the bolts to 9 Nm (7 ft. lbs.). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Park Brake Warning Lamp Switch Bolt .................................................................................................................................................. 3 Nm (25 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Specifications > Page 1186 Parking Brake Warning Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Specifications > Page 1187 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the body wiring harness junction block but do not disconnect the harness. 2. Remove the park brake warning lamp switch mounting bolt. 3. Remove the park brake warning lamp switch. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake lamp switch mounting bolt. Tighten the bolt to 3 Nm (25 inch lbs.). 3. Install the body wiring harness junction block. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 1191 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Stabilitrak Traction Control Switch: Service and Repair Stabilitrak Traction Control Switch Replacement (Stabilitrak) Removal Procedure 1. Remove Instrument Panel (IP) bezel. 2. Gently lift the retaining tabs (2) and remove the stabilitrak switch (3) from the instrument panel (IP) assembly (1). 3. Disconnect the harness connector from the stabilitrak switch. Installation Procedure 1. Connect the harness connector to the stabilitrak switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Stabilitrak > Page 1194 2. Install the stabilitrak switch (3) into the Instrument Panel (IP) assembly (1) 3. Ensure that the switch is secure into both retaining tabs (2). 4. Install instrument panel (IP) bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Stabilitrak > Page 1195 Traction Control Switch: Service and Repair Traction Control Traction Control Switch Replacement (Traction Control) Removal Procedure 1. Remove instrument panel (IP) bezel. 2. Gently lift the switch retaining tabs (1) and remove the traction control switch (2) from the Instrument Panel (IP) assembly (3). 3. Disconnect the harness connector from the traction control switch. Installation Procedure 1. Connect the harness connector to the traction control switch. 2. Install the traction control switch (2) into the instrument panel (IP) assembly (3), making sure that all of the switch retaining tabs (1) are engaged. 3. Install Instrument Panel (IP) bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 05068C Date: 080306 Recall - Possible Front Wheel Speed Sensor Corrosion SAFETY Bulletin No.: 05068C Date: March 06, 2008 Subject: 05068C - FRONT WHEEL SPEED SENSOR CORROSION Models: 1999-2002 CHEVROLET SILVERADO 2000-2002 CHEVROLET TAHOE, SUBURBAN 2002 CHEVROLET AVALANCHE 1999-2002 GMC SIERRA 2000-2002 GMC YUKON, YUKON XL LOCATED IN THE SEVERE CORROSION AREAS LISTED BELOW Supercede: Some breakpoints in this bulletin have been revised. Additional vehicles that have moved into the severe corrosion areas have been added. Please discard all copies of bulletin 05068B, issued April 2006. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in the areas shown above. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is traveling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph) the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited a crash could occur. Correction Dealers are to inspect clean and treat the affected area. In some cases the front wheel speed sensor may require replacement. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1204 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1205 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra and 2000-2002 GMC Yukon, Yukon XL vehicles located in severe corrosion areas and built within the VIN breakpoints shown. Important: Dealers retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required order appropriate part from GMSPO. Customer Reimbursement All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center not by dealers. Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement. Claim Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1206 Submit a Product Recall Claim with the information shown. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. All unsold new vehicles in dealers possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers regardless of mileage age of vehicle or ownership from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory and for which there is no customer information indicated on the dealer listing are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose since the customer may not as yet have received the notification letter. In summary whenever a vehicle subject to this recall enters your vehicle inventory or is in your dealership for service in the future you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1207 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. 1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire or equivalent whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1208 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). ^ If the sensor mounting surface is NOT flat (1) the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2) the sensor IS to be reused. Proceed to Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1209 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed harness electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame upper control arm and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush sandpaper emery cloth scotch-brite or equivalent thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust or corrosion. 18. Using compressed air remove all debris from the bearing hub surface. 19. Using a clean shop towel clean the sensor and the 0-ring. Important: While the corrosion inhibitor is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes) apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1210 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 N.m (13 lb ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated after the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply threadlocker to the threads of the bolts. 28. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles - 175 N.m (129 lb ft) ^ 2500 Series vehicles - 300 N.m (221 lb ft) 29. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 N.m (140 lb ft). 30. Complete Steps 21-30 on the opposite side front wheel speed sensor. 31. Lower the vehicle. 32. With the engine OFF gradually apply the brake pedal to approximately 2/3 of its travel distance. 33. Slowly release the brake pedal. 34. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1211 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > NHTSA05V379000 > Aug > 05 > Recall 05V379000: Wheel Speed Sensor Cleaning Wheel Speed Sensor: Recalls Recall 05V379000: Wheel Speed Sensor Cleaning MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Avalanche 1999-2002 Chevrolet/Silverado 1999-2002 Chevrolet/Suburban 1999-2002 Chevrolet/Tahoe 1999-2002 GMC/Sierra 1999-2002 GMC/Yukon 1999-2002 GMC/Yukon XL 1999-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBE : 05V379000 MFG'S REPORT DATE: August 29, 2005 COMPONENT: Service Brakes, Hydraulic: Antilock POTENTIAL NUMBER OF UNITS AFFECTED: 804000 SUMMARY: Certain pickup trucks and sport utility vehicles may experience unwanted Antilock Brake System (ABS) activation. This condition is more likely to occur in environmentally corrosive areas. This recall will be launched in the "SALT BELT" states of Connecticut, Illinois, Indiana, Massachusetts, Maine, Michigan, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont and West Virginia only. CONSEQUENCE: This can cause increased stopping distances during low-speed brake applications, which could result in a crash. REMEDY: Dealers are to remove the wheel speed sensor and thoroughly clean the wheel speed sensor mounting surface on the bearing, apply rust inhibitor to the cleaned surface, grease the mounting surface, reinstall the wheel speed sensor, and check the peak-to-peak output voltage to ensure the wheel speed signal is within specifications. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05068. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 04094 Date: 050125 Recall - Front Wheel Speed Sensor Corrosion Product Safety - Front Wheel Speed Sensor Corrosion # 04094 - (Jan 25, 2005) Models: 1999-2002 Chevrolet Silverado 2000-2002 Chevrolet Tahoe, Suburban 2002 Chevrolet Avalanche 1999-2002 GMC Sierra 2000-2002 GMC Yukon, Yukon XL Located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, Prince Edward Island Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is travelling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph), the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited, a crash could occur. Correction Dealers are to clean and treat the affected area, and in some cases, replace the front wheel speed sensor. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1220 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1221 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required, order appropriate part from GMSPO. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1222 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by January 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. ^ Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1223 Claim Information Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1224 not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. A. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. B. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. C. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1225 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped, remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinist's scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1226 ^ If the sensor mounting surface is NOT flat (1), the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2), the sensor IS to be reused. Proceed to Step 16. 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed sensor electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame, upper control arm, and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush, sandpaper, emery cloth, scotch brite, or equivalent, thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust of corrosion. 18. Using compressed air, remove all debris from the bearing hub surface. 19. Using a clean shop towel, clean the sensor and the 0-ring. Important: While the corrosion is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin, to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 Nm (13 lb-ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmVs. If the reading is less than Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1227 350 ACmVs, the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated afier the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 28. Remove all traces of the original adhesive patch. A. Clean the threads of the bolt with brake parts cleaner, or the equivalent, and allow to dry. B. Apply threadlocker to the threads of the bolts. 29. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles -- 175 Nm (129 lb-ft) ^ 2500 Series vehicles -- 300 Nm (221 lb-ft) 30. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 Nm (140 lb-ft). 31. Complete Steps 21-30 on the opposite side front wheel speed sensor. 32. Lower the vehicle. 33. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 34. Slowly release the brake pedal. 35. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1228 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: Customer Interest Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 1234 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 1240 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 05068C Date: 080306 Recall - Possible Front Wheel Speed Sensor Corrosion SAFETY Bulletin No.: 05068C Date: March 06, 2008 Subject: 05068C - FRONT WHEEL SPEED SENSOR CORROSION Models: 1999-2002 CHEVROLET SILVERADO 2000-2002 CHEVROLET TAHOE, SUBURBAN 2002 CHEVROLET AVALANCHE 1999-2002 GMC SIERRA 2000-2002 GMC YUKON, YUKON XL LOCATED IN THE SEVERE CORROSION AREAS LISTED BELOW Supercede: Some breakpoints in this bulletin have been revised. Additional vehicles that have moved into the severe corrosion areas have been added. Please discard all copies of bulletin 05068B, issued April 2006. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in the areas shown above. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is traveling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph) the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited a crash could occur. Correction Dealers are to inspect clean and treat the affected area. In some cases the front wheel speed sensor may require replacement. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1245 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1246 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra and 2000-2002 GMC Yukon, Yukon XL vehicles located in severe corrosion areas and built within the VIN breakpoints shown. Important: Dealers retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required order appropriate part from GMSPO. Customer Reimbursement All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center not by dealers. Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement. Claim Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1247 Submit a Product Recall Claim with the information shown. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. All unsold new vehicles in dealers possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers regardless of mileage age of vehicle or ownership from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory and for which there is no customer information indicated on the dealer listing are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose since the customer may not as yet have received the notification letter. In summary whenever a vehicle subject to this recall enters your vehicle inventory or is in your dealership for service in the future you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1248 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. 1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire or equivalent whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1249 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). ^ If the sensor mounting surface is NOT flat (1) the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2) the sensor IS to be reused. Proceed to Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1250 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed harness electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame upper control arm and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush sandpaper emery cloth scotch-brite or equivalent thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust or corrosion. 18. Using compressed air remove all debris from the bearing hub surface. 19. Using a clean shop towel clean the sensor and the 0-ring. Important: While the corrosion inhibitor is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes) apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1251 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 N.m (13 lb ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated after the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply threadlocker to the threads of the bolts. 28. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles - 175 N.m (129 lb ft) ^ 2500 Series vehicles - 300 N.m (221 lb ft) 29. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 N.m (140 lb ft). 30. Complete Steps 21-30 on the opposite side front wheel speed sensor. 31. Lower the vehicle. 32. With the engine OFF gradually apply the brake pedal to approximately 2/3 of its travel distance. 33. Slowly release the brake pedal. 34. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1252 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > NHTSA05V379000 > Aug > 05 > Recall 05V379000: Wheel Speed Sensor Cleaning Wheel Speed Sensor: All Technical Service Bulletins Recall 05V379000: Wheel Speed Sensor Cleaning MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Avalanche 1999-2002 Chevrolet/Silverado 1999-2002 Chevrolet/Suburban 1999-2002 Chevrolet/Tahoe 1999-2002 GMC/Sierra 1999-2002 GMC/Yukon 1999-2002 GMC/Yukon XL 1999-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBE : 05V379000 MFG'S REPORT DATE: August 29, 2005 COMPONENT: Service Brakes, Hydraulic: Antilock POTENTIAL NUMBER OF UNITS AFFECTED: 804000 SUMMARY: Certain pickup trucks and sport utility vehicles may experience unwanted Antilock Brake System (ABS) activation. This condition is more likely to occur in environmentally corrosive areas. This recall will be launched in the "SALT BELT" states of Connecticut, Illinois, Indiana, Massachusetts, Maine, Michigan, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont and West Virginia only. CONSEQUENCE: This can cause increased stopping distances during low-speed brake applications, which could result in a crash. REMEDY: Dealers are to remove the wheel speed sensor and thoroughly clean the wheel speed sensor mounting surface on the bearing, apply rust inhibitor to the cleaned surface, grease the mounting surface, reinstall the wheel speed sensor, and check the peak-to-peak output voltage to ensure the wheel speed signal is within specifications. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05068. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 04094 Date: 050125 Recall - Front Wheel Speed Sensor Corrosion Product Safety - Front Wheel Speed Sensor Corrosion # 04094 - (Jan 25, 2005) Models: 1999-2002 Chevrolet Silverado 2000-2002 Chevrolet Tahoe, Suburban 2002 Chevrolet Avalanche 1999-2002 GMC Sierra 2000-2002 GMC Yukon, Yukon XL Located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, Prince Edward Island Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is travelling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph), the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited, a crash could occur. Correction Dealers are to clean and treat the affected area, and in some cases, replace the front wheel speed sensor. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1261 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1262 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required, order appropriate part from GMSPO. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1263 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by January 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. ^ Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1264 Claim Information Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1265 not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. A. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. B. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. C. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1266 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped, remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinist's scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1267 ^ If the sensor mounting surface is NOT flat (1), the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2), the sensor IS to be reused. Proceed to Step 16. 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed sensor electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame, upper control arm, and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush, sandpaper, emery cloth, scotch brite, or equivalent, thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust of corrosion. 18. Using compressed air, remove all debris from the bearing hub surface. 19. Using a clean shop towel, clean the sensor and the 0-ring. Important: While the corrosion is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin, to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 Nm (13 lb-ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmVs. If the reading is less than Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1268 350 ACmVs, the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated afier the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 28. Remove all traces of the original adhesive patch. A. Clean the threads of the bolt with brake parts cleaner, or the equivalent, and allow to dry. B. Apply threadlocker to the threads of the bolts. 29. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles -- 175 Nm (129 lb-ft) ^ 2500 Series vehicles -- 300 Nm (221 lb-ft) 30. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 Nm (140 lb-ft). 31. Complete Steps 21-30 on the opposite side front wheel speed sensor. 32. Lower the vehicle. 33. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 34. Slowly release the brake pedal. 35. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1269 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 1275 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 05068C Date: 080306 Recall - Possible Front Wheel Speed Sensor Corrosion SAFETY Bulletin No.: 05068C Date: March 06, 2008 Subject: 05068C - FRONT WHEEL SPEED SENSOR CORROSION Models: 1999-2002 CHEVROLET SILVERADO 2000-2002 CHEVROLET TAHOE, SUBURBAN 2002 CHEVROLET AVALANCHE 1999-2002 GMC SIERRA 2000-2002 GMC YUKON, YUKON XL LOCATED IN THE SEVERE CORROSION AREAS LISTED BELOW Supercede: Some breakpoints in this bulletin have been revised. Additional vehicles that have moved into the severe corrosion areas have been added. Please discard all copies of bulletin 05068B, issued April 2006. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in the areas shown above. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is traveling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph) the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited a crash could occur. Correction Dealers are to inspect clean and treat the affected area. In some cases the front wheel speed sensor may require replacement. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1281 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1282 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra and 2000-2002 GMC Yukon, Yukon XL vehicles located in severe corrosion areas and built within the VIN breakpoints shown. Important: Dealers retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required order appropriate part from GMSPO. Customer Reimbursement All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center not by dealers. Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement. Claim Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1283 Submit a Product Recall Claim with the information shown. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. All unsold new vehicles in dealers possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers regardless of mileage age of vehicle or ownership from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory and for which there is no customer information indicated on the dealer listing are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose since the customer may not as yet have received the notification letter. In summary whenever a vehicle subject to this recall enters your vehicle inventory or is in your dealership for service in the future you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1284 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. 1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire or equivalent whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1285 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). ^ If the sensor mounting surface is NOT flat (1) the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2) the sensor IS to be reused. Proceed to Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1286 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed harness electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame upper control arm and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush sandpaper emery cloth scotch-brite or equivalent thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust or corrosion. 18. Using compressed air remove all debris from the bearing hub surface. 19. Using a clean shop towel clean the sensor and the 0-ring. Important: While the corrosion inhibitor is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes) apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1287 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 N.m (13 lb ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated after the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply threadlocker to the threads of the bolts. 28. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles - 175 N.m (129 lb ft) ^ 2500 Series vehicles - 300 N.m (221 lb ft) 29. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 N.m (140 lb ft). 30. Complete Steps 21-30 on the opposite side front wheel speed sensor. 31. Lower the vehicle. 32. With the engine OFF gradually apply the brake pedal to approximately 2/3 of its travel distance. 33. Slowly release the brake pedal. 34. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 1288 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > NHTSA05V379000 > Aug > 05 > Recall 05V379000: Wheel Speed Sensor Cleaning Wheel Speed Sensor: All Technical Service Bulletins Recall 05V379000: Wheel Speed Sensor Cleaning MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Avalanche 1999-2002 Chevrolet/Silverado 1999-2002 Chevrolet/Suburban 1999-2002 Chevrolet/Tahoe 1999-2002 GMC/Sierra 1999-2002 GMC/Yukon 1999-2002 GMC/Yukon XL 1999-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBE : 05V379000 MFG'S REPORT DATE: August 29, 2005 COMPONENT: Service Brakes, Hydraulic: Antilock POTENTIAL NUMBER OF UNITS AFFECTED: 804000 SUMMARY: Certain pickup trucks and sport utility vehicles may experience unwanted Antilock Brake System (ABS) activation. This condition is more likely to occur in environmentally corrosive areas. This recall will be launched in the "SALT BELT" states of Connecticut, Illinois, Indiana, Massachusetts, Maine, Michigan, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont and West Virginia only. CONSEQUENCE: This can cause increased stopping distances during low-speed brake applications, which could result in a crash. REMEDY: Dealers are to remove the wheel speed sensor and thoroughly clean the wheel speed sensor mounting surface on the bearing, apply rust inhibitor to the cleaned surface, grease the mounting surface, reinstall the wheel speed sensor, and check the peak-to-peak output voltage to ensure the wheel speed signal is within specifications. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05068. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 04094 Date: 050125 Recall - Front Wheel Speed Sensor Corrosion Product Safety - Front Wheel Speed Sensor Corrosion # 04094 - (Jan 25, 2005) Models: 1999-2002 Chevrolet Silverado 2000-2002 Chevrolet Tahoe, Suburban 2002 Chevrolet Avalanche 1999-2002 GMC Sierra 2000-2002 GMC Yukon, Yukon XL Located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, Prince Edward Island Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is travelling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph), the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited, a crash could occur. Correction Dealers are to clean and treat the affected area, and in some cases, replace the front wheel speed sensor. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1297 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1298 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required, order appropriate part from GMSPO. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1299 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by January 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. ^ Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1300 Claim Information Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1301 not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. A. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. B. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. C. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1302 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped, remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinist's scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1303 ^ If the sensor mounting surface is NOT flat (1), the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2), the sensor IS to be reused. Proceed to Step 16. 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed sensor electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame, upper control arm, and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush, sandpaper, emery cloth, scotch brite, or equivalent, thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust of corrosion. 18. Using compressed air, remove all debris from the bearing hub surface. 19. Using a clean shop towel, clean the sensor and the 0-ring. Important: While the corrosion is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin, to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 Nm (13 lb-ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmVs. If the reading is less than Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1304 350 ACmVs, the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated afier the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 28. Remove all traces of the original adhesive patch. A. Clean the threads of the bolt with brake parts cleaner, or the equivalent, and allow to dry. B. Apply threadlocker to the threads of the bolts. 29. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles -- 175 Nm (129 lb-ft) ^ 2500 Series vehicles -- 300 Nm (221 lb-ft) 30. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 Nm (140 lb-ft). 31. Complete Steps 21-30 on the opposite side front wheel speed sensor. 32. Lower the vehicle. 33. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 34. Slowly release the brake pedal. 35. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 1305 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1306 Wheel Speed Sensor: Specifications Front Wheel Speed Sensor Mounting Bolt ............................................................................................................................................... 18 Nm (13 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1307 Wheel Speed Sensor - RF (4WD) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > LF Wheel Speed Sensor (WSS) - LF Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > LF > Page 1310 Wheel Speed Sensor (WSS) - RF Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 1311 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor (2). 4. Remove the Wheel Speed Sensor (WSS) mounting bolt. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 5. Remove the wheel speed sensor (5) from the hub/bearing assembly (4). 6. Remove the WSS cable mounting clip from the knuckle. 7. Remove the WSS cable mounting clip from the upper control arm. 8. Remove the WSS cable mounting clip from the frame attachment point. 9. Remove the WSS cable electrical connector. Installation Procedure 1. Install the WSS (5) into the hub/bearing assembly (4). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the WSS mounting bolt. Tighten the WSS mounting bolt to 18 Nm (13 ft. lbs.). 3. Install the WSS cable mounting clip to the knuckle. 4. Install the WSS cable mounting clip to the upper control arm. 5. Install the WSS cable mounting clip to the frame attachment point. 6. Connect the WSS cable electrical connector. 7. Install the brake rotor (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 1312 8. Install the tire and wheel. 9. Return to Diagnostic Starting Point - Antilock Brake System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Specifications Yaw Rate Sensor: Specifications Yaw Rate Sensor/Lateral Accelerometer Nut ........................................................................................................................................ 10 Nm (89 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Specifications > Page 1316 Yaw Rate Sensor: Service and Repair Yaw Rate Sensor/Lateral Accelerometer Replacement Removal Procedure 1. Remove the front floor console bezel. 2. Disconnect the yaw rate sensor/lateral accelerometer electrical connector. 3. Remove the 3 yaw rate sensor/lateral accelerometer nuts. 4. Remove the yaw rate sensor/lateral accelerometer from the vehicle. Installation Procedure Important: Use care not to bend or distort the bracket that supports the yaw rate sensor/lateral accelerometer. 1. Install the yaw rate sensor/lateral accelerometer to the bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 yaw rate sensor/lateral accelerometer nuts to the bracket. Tighten the nuts to 10 Nm (89 inch lbs.). 3. Connect the yaw rate sensor/lateral accelerometer electrical connector. 4. Install the front floor bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1322 Engine Coolant Temperature (ECT) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1323 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.. 3. Drain the cooling system below the level of the ECT sensor. Refer to Draining and Filling Cooling System in Cooling System. 4. Lower the vehicle. 5. Disconnect the electrical connector from the engine coolant temperature (ECT) sensor. 6. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: ^ Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. ^ Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1324 1. Coat the ECT sensor threads with sealer GM P/N 12346004 or the equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Specifications Oil Level Sensor: Specifications Oil Level Sensor .................................................................................................................................. ................................................ 13 Nm (115 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Specifications > Page 1329 Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Drain the engine oil. 2. Disconnect the oil level sensor electrical connector (6). 3. Remove the oil level sensor from the oil pan. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the oil level sensor to the oil pan. - Tighten the oil level sensor to 13 Nm (115 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Specifications > Page 1330 2. Connect the oil level sensor electrical connector (6). 3. Fill the engine oil. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Page 1337 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement - Tools Required J 41712 Oil Pressure Sensor Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Page 1338 1. Apply sealant GM U.S. P/N 12346004, Canada P/N 10953480, or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. - Tighten the oil pressure sensor to 20 Nm (15 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper Air Temperature Sensor - Upper Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper > Page 1345 Air Temperature Sensor - Lower Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper > Page 1346 Air Temperature Sensor - Ambient Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper > Page 1347 Air Temperature Sensor - Lower Auxiliary Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper > Page 1348 Air Temperature Sensor Assembly - Inside (Over Head) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 1349 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL PROCEDURE 1. Remove the Park/Turn Signal. 2. Disconnect the electrical connector from the ambient air temperature sensor (3). 3. Remove the ambient air temperature sensor (3). INSTALLATION PROCEDURE 1. Install the ambient air temperature sensor (3). 2. Connect the electrical connector to the ambient air temperature sensor (3). 3. Install the Park/Turn Signal. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams HVAC Blower Motor Control Switch - C2 (Part Of HVAC Control Assembly) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Page 1353 Blower Motor Switch: Service and Repair BLOWER MOTOR SWITCH REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Separate the front of the console (1) from the headliner. 2. Remove the blower motor switch (2) by releasing the tabs at the rear of the switch housing. 3. Disconnect the electrical connector (3). INSTALLATION PROCEDURE 1. Connect the electrical connector (3). 2. Install the blower motor switch (2) to the switch housing. 3. Install the console (1) to the headliner. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair Cabin Temperature Sensor / Switch: Service and Repair INSIDE AIR TEMPERATURE SENSOR REPLACEMENT (OVERHEAD) REMOVAL PROCEDURE 1. Remove the left windshield garnish molding. 2. Remove the left center pillar assist handle. 3. Remove the left center pillar garnish molding. 4. Remove the left sunshade. 5. Remove the retaining screws from the headliner. 6. Gently pull down the headliner. 7. Remove the inside air temperature sensor from the headliner. 8. Disconnect the electrical connector from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Page 1357 1. Install the inside air temperature sensor to the headliner. 2. Connect the electrical connector to the inside air temperature sensor. 3. Install the screws to the headliner. 4. Install the left sunshade. 5. Install the left center pillar garnish molding. 6. Install the left center assist handle. 7. Install the left windshield garnish molding. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Air Temperature Sensor-Upper Auxiliary Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Air Temperature Sensor-Upper Auxiliary > Page 1362 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper REMOVAL PROCEDURE 1. Remove the radio. 2. Disconnect the electrical connector from the upper duct air temperature sensor. 3. Remove the upper duct air temperature sensor from the air duct by prying out of the duct. INSTALLATION PROCEDURE 1. Install the upper duct air temperature sensor to the air duct. 2. Connect the electrical connector to the upper duct air temperature sensor. 3. Install the radio. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper > Page 1365 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper Auxiliary REMOVAL PROCEDURE 1. Remove the right side C-Pillar Trim Panel. 2. Disconnect the electrical connector from the rear upper A/C temperature sensor (11). 3. Remove the rear upper A/C temperature sensor (11) from the air distribution duct. INSTALLATION PROCEDURE 1. Install the rear upper A/C temperature sensor (11) to the air distribution duct. 2. Connect the electrical connector to the rear upper A/C temperature sensor (11). 3. Install the right side C-Pillar Trim Panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper > Page 1366 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower REMOVAL PROCEDURE 1. Remove the lower duct air temperature sensor (3) and wiring harness assembly from the floor air outlet (2). 2. Disconnect the electrical connector from the lower duct air temperature sensor (3). INSTALLATION PROCEDURE 1. Connect the lower duct air temperature sensor (3) to the electrical connector. 2. Install the lower duct air temperature sensor (3) and wiring harness assembly to the floor air outlet (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper > Page 1367 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Auxiliary REMOVAL PROCEDURE 1. Remove the right side C-Pillar Trim Panel. 2. Disconnect the electrical connector from the auxiliary lower A/C temperature sensor (10). 3. Remove the auxiliary lower A/C temperature sensor (10) from the air distribution duct. INSTALLATION PROCEDURE 1. Install the rear lower A/C temperature sensor (10) to the air distribution duct. 2. Connect the electrical connector to the rear lower A/C temperature sensor (10). 3. Install the right side C-Pillar Trim Panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Diagnose A/C Low Pressure Switch Low Pressure Sensor / Switch: Technical Service Bulletins Air Conditioning - Diagnose A/C Low Pressure Switch INFORMATION Bulletin No.: 04-01-38-010A Date: January 21, 2010 Subject: Diagnostic Information to Accurately Diagnose A/C Low Pressure Switch Using Kent Moore Special Tool GE-47742 Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2007 Chevrolet Silverado 2000-2006 Chevrolet Suburban, Tahoe 2002-2007 Chevrolet Avalanche 1999-2007 GMC Sierra 2000-2006 GMC Yukon, Yukon XL 2001-2006 GMC Yukon Denali XL 2001-2007 GMC Sierra Denali, Yukon Denali XL 2003-2008 HUMMER H2 with Air Conditioning Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 04-01-38-010 (Section 01 - HVAC). Currently, technicians cannot accurately determine the air conditioning (A/C) low pressure switch open/close pressure point by measuring pressure at the low side service port. This is because the evaporator is between the low side service port and the A/C low pressure switch. Correlating pressures measured at the low side service port to actual pressures at the A/C low pressure switch port is difficult because of the multiple variables that impact pressure drop across the evaporator. Providing a pressure range that would take into account all these variables would result in a pressure range that would be too broad to be useful for diagnostic purposes. Kent Moore special tool GE-47742 will allow technicians to monitor the actual pressures at which the A/C low pressure switch opens and closes under actual operating conditions. Technicians are to use the following steps to install and use Kent Moore special tool GE-47742 to measure A/C low pressure switch opening and closing pressures: 1. Disconnect the wire harness from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Install the A/C low pressure switch, using the threaded port with an O-ring, onto special tool GE-47742. 4. Install special tool GE-47742, with the A/C low pressure switch attached, onto the accumulator. Important Removing the seal from the A/C low pressure switch wire harness connector is required. Failure to remove the seal before plugging it into the switch will lead to misdiagnosis. The "plunger effect" of plugging the connector with a seal into the A/C low pressure switch induces a pressure on the back side of the switch. This pressure will skew the opening/closing characteristics of the switch 34-69 kPa (5-10 psi) until the pressure bleeds off. The time required for the connection induced pressure to bleed off can be 20 minutes or longer. 5. Remove the seal from the A/C low pressure switch wire harness connector. 6. Connect the wire harness, without the seal, to the A/C low pressure switch. 7. Connect the low side service hose from the ACR2000(R) or GE-48800 to the service port on special tool GE-47742. 8. Connect a Tech2(R) to the vehicle. 9. Start the vehicle and maintain an engine speed of 1500 RPM. Set the HVAC controls as follows: - Set the A/C control switch to ON. - Set the mode control switch to A/C and engage recirculation mode. - Set the blower motor speed to LOW. - Set the temperature control to full cold. - Set the auxiliary blower motor speed to LOW. If equipped. - Set the auxiliary temperature control to full cold. If equipped. - The vehicle must be operating with no sun load (in the shade). 10. Use the Tech2(R) to determine the A/C low pressure switch status and the ACR2000(R) or GE-48800 to determine the A/C low side pressure. Simultaneously monitor the switch status and the pressure at which the A/C low pressure switch opens and closes. The Tech2(R) will display switch status as "Normal" for Closed and "Low Pressure" for Open. A properly operating switch should open between 138-172 kPa (20-25 psi) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Diagnose A/C Low Pressure Switch > Page 1373 and close between 275-317 kPa (40-46 psi). 11. Remove special tool GE-47742 after diagnosis is complete. 12. Install a new O-ring on the A/C low pressure switch port on the accumulator. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 13. Install the A/C low pressure switch onto the accumulator. Tighten Tighten the A/C low pressure switch to 6 Nm (44 lb in). Important Remember to install the seal back onto the A/C low pressure switch wire harness connector. Failure to replace the seal could result in terminal corrosion. 14. Reconnect the wire harness to the A/C low pressure switch. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1377 Sunload Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1378 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel upper trim pad. 2. Turn the Sun Load Sensor (2)1/4 turn and remove it from the upper trim pad. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the sun load sensor (2) to the upper trim pad turning it 1/4 turn to secure it in place. 3. Install the instrument panel upper trim pad. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1384 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1385 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1386 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1387 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1388 Dimmer Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1389 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1390 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1391 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1392 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1393 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1394 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1395 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1396 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1397 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1398 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1399 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1400 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1401 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1402 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1403 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1404 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1405 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1406 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1407 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1408 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1409 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1410 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1411 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1412 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1413 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1414 Dimmer Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo Door Ajar Switch - Right Cargo Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 1419 Mini Wedge (Door Jamb Switch) - LF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 1420 Mini Wedge (Door Jamb Switch) - LF - C1 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 1421 Mini Wedge (Door Jamb Switch) - LF - C3 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 1422 Door Switch: Diagrams Door Ajar Switch - Right Cargo Mini Wedge (Door Jamb Switch) - LF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 1423 Mini Wedge (Door Jamb Switch) - LF - C1 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - LF - C3 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 1424 Mini Wedge (Door Jamb Switch) - RF - C1 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - RF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 1425 Mini Wedge (Door Jamb Switch) - RF - C3 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - C1 - LR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 1426 Mini Wedge (Door Jamb Switch) - C1 - RR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: Customer Interest Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge > Page 1435 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge > Page 1436 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge > Page 1442 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge > Page 1443 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 1444 Fuel Gauge Sender: Specifications Fuel Level Specifications Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 1445 Fuel Level Specifications Part 2 The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 1446 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 1447 Fuel Gauge Sender: Diagrams Fuel Pump/Sender - Secondary Fuel Pump/Sender - Primary Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 1448 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The Powertrain Control Module (PCM) sends the fuel level information via the class 2 circuit to the Instrument Panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 1449 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the retaining clip (6) from the fuel level sensor connector. 4. Disconnect the electrical connector (7) from under the fuel sender cover. 5. Remove the sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip (4). 3. Connect the electrical connector (7) to the fuel level sensor. 4. Connect the retaining clip (6) to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Park Brake Warning Lamp Switch Bolt .................................................................................................................................................. 3 Nm (25 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Specifications > Page 1453 Parking Brake Warning Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Specifications > Page 1454 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the body wiring harness junction block but do not disconnect the harness. 2. Remove the park brake warning lamp switch mounting bolt. 3. Remove the park brake warning lamp switch. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake lamp switch mounting bolt. Tighten the bolt to 3 Nm (25 inch lbs.). 3. Install the body wiring harness junction block. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions Ambient Light Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1460 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1461 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1462 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1463 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1464 Ambient Light Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1465 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1466 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1467 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1468 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1469 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1470 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1471 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1472 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1473 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1474 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1475 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1476 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1477 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1478 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1479 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1480 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1481 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1482 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1483 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1484 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1485 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1486 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1487 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1488 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1489 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1490 Ambient Light Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 1491 Ambient Light Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the instrument panel top cover. 2. Disconnect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Turn the ambient light sensor 1/4 turn and remove it from the IP top cover. INSTALLATION PROCEDURE 1. Install the ambient light sensor to the underside of the IP top cover, turning it 1/4 turn to secure it in place. 2. Connect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Install the instrument panel top cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1496 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1497 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1498 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1499 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1500 Backup Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1501 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1502 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1503 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1504 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1505 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1506 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1507 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1508 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1509 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1510 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1511 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1512 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1513 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1514 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1515 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1516 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1517 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1518 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1519 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1520 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1521 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1522 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1523 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1524 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1525 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Light Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1531 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1532 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1533 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1534 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1535 Brake Light Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1536 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1537 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1538 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1539 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1540 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1541 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1542 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1543 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1544 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1545 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1546 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1547 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1548 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1549 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1550 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1551 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1552 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1553 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1554 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1555 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1556 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1557 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1558 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1559 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1560 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1561 Stop Lamp Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 1562 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement Removal Procedure 1. Disconnect the electrical connector from the stop lamp switch (2). 2. Remove the pushrod retaining clip (4). 3. Remove the stop lamp switch (2). Installation Procedure 1. Install the stop lamp switch (2). 2. Install the pushrod retaining clip (4). 3. Connect the electrical connector to the stop lamp switch (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Cargo Lamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1568 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1569 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1570 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1571 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1572 Cargo Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1573 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1574 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1575 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1576 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1577 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1578 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1579 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1580 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1581 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1582 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1583 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1584 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1585 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1586 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1587 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1588 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1589 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1590 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1591 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1592 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1593 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1594 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1595 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1596 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1597 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1598 Cargo Lamp Switch: Connector Views Fog/Cargo Lamp Switch Part 2 Fog/Cargo Lamp Switch Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Page 1599 Cargo Lamp Switch: Service and Repair LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions Combination Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1604 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1605 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1606 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1607 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1608 Combination Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1609 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1610 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1611 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1612 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1613 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1614 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1615 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1616 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1617 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1618 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1619 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1620 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1621 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1622 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1623 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1624 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1625 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1626 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1627 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1628 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1629 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1630 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1631 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1632 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1633 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo Door Ajar Switch - Right Cargo Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 1638 Mini Wedge (Door Jamb Switch) - LF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 1639 Mini Wedge (Door Jamb Switch) - LF - C1 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 1640 Mini Wedge (Door Jamb Switch) - LF - C3 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 1641 Door Switch: Diagrams Door Ajar Switch - Right Cargo Mini Wedge (Door Jamb Switch) - LF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 1642 Mini Wedge (Door Jamb Switch) - LF - C1 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - LF - C3 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 1643 Mini Wedge (Door Jamb Switch) - RF - C1 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - RF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 1644 Mini Wedge (Door Jamb Switch) - RF - C3 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - C1 - LR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 1645 Mini Wedge (Door Jamb Switch) - C1 - RR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations Fog/Driving Lamp Switch: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 1649 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Fog/Driving Lamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1652 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1653 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1654 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1655 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1656 Fog/Driving Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1657 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1658 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1659 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1660 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1661 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1662 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1663 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1664 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1665 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1666 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1667 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1668 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1669 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1670 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1671 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1672 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1673 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1674 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1675 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1676 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1677 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1678 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1679 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1680 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1681 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1682 Fog/Driving Lamp Switch: Connector Views Fog/Cargo Lamp Switch Part 2 Fog/Cargo Lamp Switch Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1683 Rear Wiper/Washer And Fog Lamp Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Lamp Switch ASSY Replacement - Front Fog Lamp and Cargo Lamp Fog/Driving Lamp Switch: Service and Repair Lamp Switch ASSY Replacement - Front Fog Lamp and Cargo Lamp REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Lamp Switch ASSY Replacement - Front Fog Lamp and Cargo Lamp > Page 1686 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement - Rear REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the fog lamp switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the fog lamp switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1691 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1692 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1693 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1694 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1695 Hazard Warning Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1696 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1697 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1698 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1699 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1700 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1701 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1702 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1703 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1704 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1705 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1706 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1707 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1708 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1709 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1710 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1711 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1712 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1713 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1714 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1715 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1716 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1717 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1718 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1719 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1720 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1725 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1726 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1727 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1728 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1729 Headlamp Dimmer Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1730 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1731 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1732 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1733 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1734 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1735 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1736 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1737 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1738 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1739 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1740 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1741 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1742 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1743 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1744 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1745 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1746 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1749 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1750 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1751 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1752 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1753 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1754 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1760 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1761 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1762 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1764 Headlamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1765 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1766 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1767 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1768 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1769 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1770 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1771 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1772 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1773 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1774 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1775 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1776 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1777 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1778 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1779 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1780 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1781 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1782 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1783 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1784 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1785 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1786 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1787 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1788 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1789 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement Headlamp Switch: Service and Repair Headlamp Switch Replacement REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Unsnap the switch from the housing. 3. Disconnect the electrical connectors. 4. Remove the switch. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement > Page 1792 1. Connect the electrical connectors. 2. Install the headlamp switch by snapping the headlamps switch into place. 3. Install the bezel to the instrument panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement > Page 1793 Headlamp Switch: Service and Repair Headlamp Leveling Switch Replacement REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the head lamp leveling switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the head lamp leveling switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1798 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1799 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1800 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1801 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1802 Turn Signal Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1803 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1804 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1805 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1806 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1807 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1808 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1809 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1810 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1811 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1812 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1813 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1814 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1815 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1816 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1817 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1818 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1819 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1820 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1821 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1822 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1823 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1824 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1825 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1826 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1827 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Underhood Lamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1832 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1833 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1834 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1835 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1836 Underhood Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1837 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1838 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1839 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1840 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1841 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1842 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1843 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1844 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1845 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1846 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1847 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1848 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1849 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1850 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1851 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1852 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1853 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1854 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1855 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1856 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1857 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1858 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1859 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1860 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1861 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1867 Accelerator Pedal Position (APP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1868 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position (APP) Sensor The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 3 individual accelerator pedal position sensors within one housing. Three separate signal, low reference, and 5-volt reference circuits are used to connect the APP and the TAC module. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 1.0 volt at 0 pedal travel to above 2.0 volts at 100 percent pedal travel. APP sensor 2 voltage should decrease from above 4.0 volts at 0 pedal travel to below 2.9 volts at 100 percent pedal travel. APP sensor 3 voltage should decrease from above 3.8 volts at 0 percent pedal travel to below 3.1 volts at 100 percent pedal travel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1869 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the left instrument panel (IP) lower closeout insulator panel. 2. Disconnect the accelerator pedal position (APP) sensor harness connector. Remove the accelerator pedal mounting bolts. 3. Remove the APP assembly. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1870 1. Install the APP assembly to the steering column support bracket. NOTE: Refer to the Fastener Notice in Service Precautions. IMPORTANT: Always use a torque wrench in order to obtain the proper torque. 2. Install the accelerator pedal mounting bolts. Tighten Tighten the accelerator pedal mounting bolts to 20 N.m (15 lb ft). 3. Connect the APP sensor harness connector. 4. Verify that the vehicle meets the following conditions: ^ The vehicle is not in a Reduced Engine Power mode. ^ The ignition is ON. ^ The engine is OFF. 5. Connect a scan tool in order to test for a proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Inspect the carpet fit under the accelerator pedal. 8. Install the left IP lower closeout insulator panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1876 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1877 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1878 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1879 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1880 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1881 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1882 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1883 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1884 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1885 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1886 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1887 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1888 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1889 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1890 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1891 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1892 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1893 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1894 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1895 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1896 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1897 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1898 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1899 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1900 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1901 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1902 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1903 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1904 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1905 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1906 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 1907 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Take care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. Do not drop or roughly handle the MAF/IAT sensor. 1. Remove air intake resonator. 2. Disconnect the MAF/IAT sensor electrical connector. 3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 1908 2. Install the MAF/IAT sensor on to the air cleaner housing. 3. Tighten the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Connect the MAF/IAT electrical connector. 5. Install air intake resonator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1914 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1915 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1916 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1917 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1918 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1919 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1920 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1921 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1922 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1923 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1924 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1925 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1926 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1927 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1928 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1929 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1930 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1931 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1932 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1933 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1934 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1935 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1936 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1937 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1938 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1939 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1940 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1941 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1942 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1943 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1944 Camshaft Position (CMP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 1945 Camshaft Position Sensor: Description and Operation The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 1946 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. Camshaft Position Sensor (CMP) 1. Remove the engine sight shield, as necessary. 2. Disconnect the CMP sensor electrical connector. 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor. INSTALLATION PROCEDURE Camshaft Position Sensor (CMP) 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CMP sensor electrical connector. 4. Install the engine sight shield, as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1950 Engine Coolant Temperature (ECT) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1951 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.. 3. Drain the cooling system below the level of the ECT sensor. Refer to Draining and Filling Cooling System in Cooling System. 4. Lower the vehicle. 5. Disconnect the electrical connector from the engine coolant temperature (ECT) sensor. 6. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: ^ Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. ^ Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1952 1. Coat the ECT sensor threads with sealer GM P/N 12346004 or the equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1958 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1959 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1960 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1961 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1962 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1963 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1964 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1965 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1966 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1967 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1968 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1969 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1970 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1971 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1972 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1973 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1974 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1975 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1976 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1977 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1978 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1979 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1980 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1981 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1982 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1983 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1984 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1985 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1986 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1987 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1988 Crankshaft Position (CKP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 1989 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at Top Dead Center (TDC). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module (PCM) for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. Observe the fuel cut-off for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: ^ Block the drive wheels. ^ Apply the vehicles parking brake. ^ Cycle the ignition from OFF to ON. ^ Apply and hold the brake pedal. ^ Start and idle the engine. ^ Turn OFF the AC. ^ Place the vehicle's transmission in Park (A/T) or Neutral (M/T). ^ The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. With the scan tool, enable the CKP system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-off is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine Mechanical. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1992 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure when the crankshaft position sensor is removed or replaced. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the starter. 4. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1993 5. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 6. Remove the CKP sensor retaining bolt. 7. Remove the CKP sensor. INSTALLATION PROCEDURE Crankshaft Position Sensor (CKP) 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor retaining fastener. Tighten Tighten the bolt to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1994 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1998 Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The Powertrain Control Module (PCM) sends the fuel level information via the class 2 circuit to the Instrument Panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1999 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the retaining clip (6) from the fuel level sensor connector. 4. Disconnect the electrical connector (7) from under the fuel sender cover. 5. Remove the sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip (4). 3. Connect the electrical connector (7) to the fuel level sensor. 4. Connect the retaining clip (6) to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2003 Fuel Tank Pressure (FTP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2004 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2005 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Remove the fuel pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel pressure sensor (1). 2. Install the fuel tank. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2009 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2010 Intake Air Temperature Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Take care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. Do not drop or roughly handle the MAF/IAT sensor. 1. Remove air intake resonator. 2. Disconnect the MAF/IAT sensor electrical connector. 3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2011 2. Install the MAF/IAT sensor on to the air cleaner housing. 3. Tighten the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Connect the MAF/IAT electrical connector. 5. Install air intake resonator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set Knock Sensor: Customer Interest Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-023A Date: June, 2002 TECHNICAL Subject: Audible Spark Knock (Detonation), MIL Illuminated, DTC P0332 Set (Replace Rear Bank Knock Sensor and RTV Area Around Sensor) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird with 5.7L Engine (VIN G - RPO LS1) 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalance 1999-2002 GMC Sierra, Yukon, Yukon XL 2002 Cadillac Escalade, Escalade EXT with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, N, U - RPOS LR4, LM7, L59, L09, L04) This bulletin is being revised to add Cadillac Escalade and Cadillac Escalade EXT to the Models. Please discard Corporate Bulletin Number 02-06-04-023 (Section 6 - Engine/Propulsion System). Condition Some customers may comment on a mild to severe engine ping (commonly referred to as spark knock), usually worse during acceleration and/or an illuminated MIL. Upon investigation, the technician may find DTC P0332 set. Cause This condition may be the result of corrosion of the rear bank knock sensor due to water intrusion into the sensor cavity. This condition is more apparent on vehicles in which customers frequently wash the engine compartment. Correction Replace the rear bank knock sensor and build a dam (wall) around the sensor using RTV to divert water away from the sensor. Use the procedure and part number listed. 1. Remove the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. 2. Remove the wiring harness assembly from the knock sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 2020 3. Remove the rear bank knock sensor. 4. Install the new rear bank knock sensor. Tighten Tighten the knock sensor to 20 N.m (15 lb ft). 5. Install the wiring harness assembly to the knock sensor. 6. Apply a bead of RTV silicone sealant approximately 9 mm (3/8 in) wide and 6 mm (1/4 in) high along the outside edge of the ridge on the engine block valley cover around the rear bank knock sensor. DO NOT form a complete circle. Leave the rear section open as shown. 7. From the underside of the intake manifold, completely remove the rear intake manifold seal (foam material). 8. Install the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 2021 For vehicles repaired under warranty, use the table as shown DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set Knock Sensor: All Technical Service Bulletins Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-023A Date: June, 2002 TECHNICAL Subject: Audible Spark Knock (Detonation), MIL Illuminated, DTC P0332 Set (Replace Rear Bank Knock Sensor and RTV Area Around Sensor) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird with 5.7L Engine (VIN G - RPO LS1) 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalance 1999-2002 GMC Sierra, Yukon, Yukon XL 2002 Cadillac Escalade, Escalade EXT with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, N, U - RPOS LR4, LM7, L59, L09, L04) This bulletin is being revised to add Cadillac Escalade and Cadillac Escalade EXT to the Models. Please discard Corporate Bulletin Number 02-06-04-023 (Section 6 - Engine/Propulsion System). Condition Some customers may comment on a mild to severe engine ping (commonly referred to as spark knock), usually worse during acceleration and/or an illuminated MIL. Upon investigation, the technician may find DTC P0332 set. Cause This condition may be the result of corrosion of the rear bank knock sensor due to water intrusion into the sensor cavity. This condition is more apparent on vehicles in which customers frequently wash the engine compartment. Correction Replace the rear bank knock sensor and build a dam (wall) around the sensor using RTV to divert water away from the sensor. Use the procedure and part number listed. 1. Remove the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. 2. Remove the wiring harness assembly from the knock sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 2027 3. Remove the rear bank knock sensor. 4. Install the new rear bank knock sensor. Tighten Tighten the knock sensor to 20 N.m (15 lb ft). 5. Install the wiring harness assembly to the knock sensor. 6. Apply a bead of RTV silicone sealant approximately 9 mm (3/8 in) wide and 6 mm (1/4 in) high along the outside edge of the ridge on the engine block valley cover around the rear bank knock sensor. DO NOT form a complete circle. Leave the rear section open as shown. 7. From the underside of the intake manifold, completely remove the rear intake manifold seal (foam material). 8. Install the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 2028 For vehicles repaired under warranty, use the table as shown DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Page 2029 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2032 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2033 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2034 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2035 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2036 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2037 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2038 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2039 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2040 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2041 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2042 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2043 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2044 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2045 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2046 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2047 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2048 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2049 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2050 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2051 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2052 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2053 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2054 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2055 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2056 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2057 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2058 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2059 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2060 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2061 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2062 Knock Sensor (KS) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2063 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: ^ The broadband single wire sensor ^ The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: ^ All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. ^ The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near Top Dead Center (TDC) of the firing stroke. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2064 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Remove the knock sensor wiring harness assembly. 3. Remove the knock sensor (KS). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2065 1. Install the knock sensor. Tighten Torque the sensor to 20 N.m (15 lb ft). 2. Install the knock sensor wiring harness assembly. 3. Install the intake manifold. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2069 Manifold Absolute Pressure (MAP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2070 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector. 3. Remove the MAP sensor (1) from the intake manifold. INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2071 1. Install the MAP sensor (1). Push the MAP sensor down in order to engage the sensor into the retainer. 2. Connect the MAP sensor electrical connector. 3. Install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2080 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2081 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2082 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2083 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2084 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2085 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2086 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2087 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2088 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2089 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2090 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2091 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2092 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2093 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2094 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2095 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2096 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2097 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2098 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2099 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2100 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2101 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2102 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2103 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2104 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2105 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2106 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2107 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2108 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2109 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2110 Oxygen Sensor: Connector Views Delphi Heated Oxygen Sensor (H02S) Bank 1 Sensor 2 (Delphi) Heated Oxygen Sensor (H02S) Bank 1 Sensor 1 (Delphi) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2111 Heated Oxygen Sensor (H02S) Bank 2 Sensor 1 (Delphi) Heated Oxygen Sensor (H02S) Bank 2 Sensor 2 (Delphi) Denso Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2112 Heated Oxygen Sensor (H02S) Bank 1 Sensor 2 (Denso) Heated Oxygen Sensor (H02S) Bank 1 Sensor 1 (Denso) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2113 Heated Oxygen Sensor (H02S) Bank 2 Sensor 1 (Denso) Heated Oxygen Sensor (H02S) Bank 2 Sensor 2 (Denso) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2114 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSORS The main function of the pre-catalyst HO2S is to provide the PCM with exhaust stream information in order to maintain proper fueling to hold emissions within acceptable levels. These oxygen sensors are always located between the exhaust manifold and the 3-way Catalytic Converter (TWC). After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases. The PCM uses the signal voltage from the fuel control HO2S in a Closed Loop in order to adjust the fuel injector pulse width. While in a Closed Loop, the PCM can adjust fuel delivery in order to maintain an air to fuel ratio which allows the best combination of emission control and driveability. If the HO2S pigtail wiring, connector, or terminal are damaged, replace the entire HO2S assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must be provided with a clean air reference. This clean air reference is obtained by way of the HO2S wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference. Any attempt to repair the wires, connectors, or terminals could degrade HO2S performance. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2117 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2118 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2119 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2120 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2121 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2122 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2123 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2129 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2130 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2131 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2132 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2133 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2134 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2135 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2136 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2137 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2138 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2139 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2140 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2141 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2142 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2143 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2144 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2145 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2146 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2147 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2148 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2149 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2150 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2151 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2152 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2153 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2154 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2155 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2156 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2157 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2158 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2159 Throttle Position Sensor: Connector Views Throttle Position (TP) Sensor Throttle Position (TP) Sensor (Dual Track) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2160 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to the Battery Disconnect Caution in Service Precautions. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result. IMPORTANT: If the vehicle is equipped with electronic throttle control (ETC) the throttle position (TP) sensor is NOT serviceable. The throttle body and TP sensor MUST be serviced as a complete assembly. 1. Disconnect the negative battery cable. 2. Remove the generator. 3. Disconnect the throttle position TP sensor electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2161 4. Remove the TP sensor attaching screws (5). 5. Remove the TP sensor (6). 6. Remove the TP sensor O-ring seal (7). INSTALLATION PROCEDURE 1. Install the TP sensor O-ring seal (7) on the TP sensor (6). 2. Install the TP sensor on the throttle body with the throttle valve in the closed position. Verify the TP sensor lever lines up with the TP sensor drive lever on the throttle shaft. NOTE: Refer to the Fastener Notice in Service Precautions. 3. Install the TP sensor attaching screws (5). Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2162 4. Connect the TP sensor electrical connector. 5. Install the generator. 6. Connect the negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 4L60-E Park/Neutral Position Switch Screw .................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E > Page 2168 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E Transmission Position Switch/Sensor: Adjustments 4L60-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E > Page 2171 Transmission Position Switch/Sensor: Adjustments 4L80-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E Transmission Position Switch/Sensor: Service and Repair 4L60-E Park Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 2174 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 2175 Transmission Position Switch/Sensor: Service and Repair 4L80-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 2176 4. Position the tool J41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2181 Accelerator Pedal Position (APP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2182 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position (APP) Sensor The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 3 individual accelerator pedal position sensors within one housing. Three separate signal, low reference, and 5-volt reference circuits are used to connect the APP and the TAC module. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 1.0 volt at 0 pedal travel to above 2.0 volts at 100 percent pedal travel. APP sensor 2 voltage should decrease from above 4.0 volts at 0 pedal travel to below 2.9 volts at 100 percent pedal travel. APP sensor 3 voltage should decrease from above 3.8 volts at 0 percent pedal travel to below 3.1 volts at 100 percent pedal travel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2183 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the left instrument panel (IP) lower closeout insulator panel. 2. Disconnect the accelerator pedal position (APP) sensor harness connector. Remove the accelerator pedal mounting bolts. 3. Remove the APP assembly. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2184 1. Install the APP assembly to the steering column support bracket. NOTE: Refer to the Fastener Notice in Service Precautions. IMPORTANT: Always use a torque wrench in order to obtain the proper torque. 2. Install the accelerator pedal mounting bolts. Tighten Tighten the accelerator pedal mounting bolts to 20 N.m (15 lb ft). 3. Connect the APP sensor harness connector. 4. Verify that the vehicle meets the following conditions: ^ The vehicle is not in a Reduced Engine Power mode. ^ The ignition is ON. ^ The engine is OFF. 5. Connect a scan tool in order to test for a proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Inspect the carpet fit under the accelerator pedal. 8. Install the left IP lower closeout insulator panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2190 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2191 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2192 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2193 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2194 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2195 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2196 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2197 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2198 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2199 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2200 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2201 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2202 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2203 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2204 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2205 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2206 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2207 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2208 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2209 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2210 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2211 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2213 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2214 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2215 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2216 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2217 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2218 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2219 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2220 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2221 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Take care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. Do not drop or roughly handle the MAF/IAT sensor. 1. Remove air intake resonator. 2. Disconnect the MAF/IAT sensor electrical connector. 3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2222 2. Install the MAF/IAT sensor on to the air cleaner housing. 3. Tighten the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Connect the MAF/IAT electrical connector. 5. Install air intake resonator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams Fuel Composition Sensor - W/L59 Only Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 2226 Flexible Fuel Sensor: Description and Operation FUEL COMPOSITION SENSOR DESCRIPTION The Fuel Composition Sensor (FCS), or flex fuel sensor (service parts term), measures the ethanol-gasoline ratio of the fuel being used in a flexible fuel vehicle. Flexible fuel vehicles can be operated with a blend of ethanol and gasoline, up to 85 percent ethanol. In order to adjust the ignition timing and the fuel quantity to be injected, the engine management system requires information about the percentage of ethanol in the fuel. The FCS uses quick-connect style fuel connections, an incoming fuel connection, and an outgoing fuel connection. The two connections have different diameters, to prevent incorrect attachment of the fuel lines. All fuel passes through the fuel composition sensor before continuing on to the fuel rail. The fuel composition sensor measures two different fuel related parameters, and sends an electrical signal to the Powertrain Control Module (PCM) to indicate ethanol percentage, and fuel temperature. The fuel composition sensor has a three-wire electrical harness connector. The three wires provide a ground circuit, a power source, and a signal output to the PCM. The power source is vehicle system voltage, +12 volts), and the ground circuit connects to chassis ground. The signal circuit carries both the ethanol percentage and fuel temperature within the same signal, on the same wire. The FCS uses a microprocessor inside the sensor to measure the ethanol percentage and fuel temp, and change an output signal accordingly. The electrical characteristic of the FCS signal is a square-wave digital signal. The signal is both variable frequency and variable pulse width. The frequency of the signal indicates the ethanol percentage, and the pulse width indicates the fuel temperature. The PCM provides an internal pull-up to five volts on the signal circuit, and the FCS pulls the 5 volts to ground in pulses. The output frequency is linear to the percentage of ethanol content in the fuel. The normal range of operating frequency is between 50 and 150 Hertz, with 50 Hertz representing 0 percent ethanol, and 150 Hertz representing 100 percent ethanol. The normal pulse width range of the digital pulses is between 1 and 5 milliseconds, with 1 millisecond representing 40°C (-40°F), and 5 milliseconds representing 125°C (257°F). The microprocessor inside the sensor is capable of a certain amount of self-diagnosis. An output frequency of 170 Hertz indicates either that the fuel is contaminated or contains methanol (it should not), or that an internal sensor electrical fault has been detected. Certain substances dissolved in the fuel can cause the fuel to be contaminated, raising the output frequency to be higher than the actual ethanol percentage should indicate. Examples of these substances include water, sodium chloride (salt), and methanol. It should be noted that it is likely that the FCS will indicate a slightly lower ethanol percentage than what is advertised at the fueling station. This is not a fault of the sensor. The reason has to do with government requirements for alcohol-based motor fuels. Government regulations require that alcohol intended for use as motor fuel be DENATURED. This means that 100 percent pure ethanol is first denatured with approximately 4% percent gasoline, before being mixed with anything else. When an ethanol gasoline mixture is advertised as E85, the 85 percent ethanol was denatured before being blended with gasoline, meaning an advertised E85 fuel contains only about 81 percent ethanol. The FCS measures the actual percentage of ethanol in the fuel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 2227 Flexible Fuel Sensor: Service and Repair FUEL COMPOSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure. 3. Raise the vehicle. 4. Remove the fuel composition sensor fuel composition sensor (FCS) attachment nuts (1). 5. Disconnect the FCS inlet and outlet pipes from the FCS. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 2228 6. Disconnect the FCS electrical connector (1). 7. Remove the FCS and bracket assembly from the frame rail. 8. Remove the FCS bolts and remove from the bracket. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 2229 1. Install the FCS to the bracket and install bolts. Tighten Tighten bolts to 10 N.m (89 lb in). 2. Install FCS and bracket assembly to frame. 3. Install FCS bracket to frame nuts. Tighten Tighten nuts (1) to 17 N.m (13 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 2230 4. Connect the FCS inlet and outlet pipes to the FCS. 5. Connect the FCS electrical connector (1). 6. Lower the vehicle. 7. Start the engine and check for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2236 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2237 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2238 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2239 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2240 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2241 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2242 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2243 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2244 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2245 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2246 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2247 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2248 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2249 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2250 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2251 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2252 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2253 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2254 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2255 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2256 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2257 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2258 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2259 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2260 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2261 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2262 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2263 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2264 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2265 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2266 Throttle Position Sensor: Connector Views Throttle Position (TP) Sensor Throttle Position (TP) Sensor (Dual Track) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 2267 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to the Battery Disconnect Caution in Service Precautions. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result. IMPORTANT: If the vehicle is equipped with electronic throttle control (ETC) the throttle position (TP) sensor is NOT serviceable. The throttle body and TP sensor MUST be serviced as a complete assembly. 1. Disconnect the negative battery cable. 2. Remove the generator. 3. Disconnect the throttle position TP sensor electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 2268 4. Remove the TP sensor attaching screws (5). 5. Remove the TP sensor (6). 6. Remove the TP sensor O-ring seal (7). INSTALLATION PROCEDURE 1. Install the TP sensor O-ring seal (7) on the TP sensor (6). 2. Install the TP sensor on the throttle body with the throttle valve in the closed position. Verify the TP sensor lever lines up with the TP sensor drive lever on the throttle shaft. NOTE: Refer to the Fastener Notice in Service Precautions. 3. Install the TP sensor attaching screws (5). Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 2269 4. Connect the TP sensor electrical connector. 5. Install the generator. 6. Connect the negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2276 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2277 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2278 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2279 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2280 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2281 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2282 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2283 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2284 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2285 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2286 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2287 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2288 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2289 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2290 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2291 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2292 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2293 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2294 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2295 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2296 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2297 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2298 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2299 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2300 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2301 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2302 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2303 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2304 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2305 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2306 Camshaft Position (CMP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2307 Camshaft Position Sensor: Description and Operation The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2308 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. Camshaft Position Sensor (CMP) 1. Remove the engine sight shield, as necessary. 2. Disconnect the CMP sensor electrical connector. 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor. INSTALLATION PROCEDURE Camshaft Position Sensor (CMP) 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CMP sensor electrical connector. 4. Install the engine sight shield, as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2314 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2315 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2316 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2317 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2318 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2319 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2320 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2321 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2322 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2323 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2324 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2325 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2326 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2327 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2328 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2329 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2330 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2331 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2332 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2333 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2334 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2335 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2336 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2337 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2338 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2339 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2340 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2341 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2342 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2343 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2344 Crankshaft Position (CKP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2345 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at Top Dead Center (TDC). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module (PCM) for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. Observe the fuel cut-off for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: ^ Block the drive wheels. ^ Apply the vehicles parking brake. ^ Cycle the ignition from OFF to ON. ^ Apply and hold the brake pedal. ^ Start and idle the engine. ^ Turn OFF the AC. ^ Place the vehicle's transmission in Park (A/T) or Neutral (M/T). ^ The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. With the scan tool, enable the CKP system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-off is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine Mechanical. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2348 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure when the crankshaft position sensor is removed or replaced. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the starter. 4. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2349 5. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 6. Remove the CKP sensor retaining bolt. 7. Remove the CKP sensor. INSTALLATION PROCEDURE Crankshaft Position Sensor (CKP) 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor retaining fastener. Tighten Tighten the bolt to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2350 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set Knock Sensor: Customer Interest Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-023A Date: June, 2002 TECHNICAL Subject: Audible Spark Knock (Detonation), MIL Illuminated, DTC P0332 Set (Replace Rear Bank Knock Sensor and RTV Area Around Sensor) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird with 5.7L Engine (VIN G - RPO LS1) 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalance 1999-2002 GMC Sierra, Yukon, Yukon XL 2002 Cadillac Escalade, Escalade EXT with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, N, U - RPOS LR4, LM7, L59, L09, L04) This bulletin is being revised to add Cadillac Escalade and Cadillac Escalade EXT to the Models. Please discard Corporate Bulletin Number 02-06-04-023 (Section 6 - Engine/Propulsion System). Condition Some customers may comment on a mild to severe engine ping (commonly referred to as spark knock), usually worse during acceleration and/or an illuminated MIL. Upon investigation, the technician may find DTC P0332 set. Cause This condition may be the result of corrosion of the rear bank knock sensor due to water intrusion into the sensor cavity. This condition is more apparent on vehicles in which customers frequently wash the engine compartment. Correction Replace the rear bank knock sensor and build a dam (wall) around the sensor using RTV to divert water away from the sensor. Use the procedure and part number listed. 1. Remove the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. 2. Remove the wiring harness assembly from the knock sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 2364 3. Remove the rear bank knock sensor. 4. Install the new rear bank knock sensor. Tighten Tighten the knock sensor to 20 N.m (15 lb ft). 5. Install the wiring harness assembly to the knock sensor. 6. Apply a bead of RTV silicone sealant approximately 9 mm (3/8 in) wide and 6 mm (1/4 in) high along the outside edge of the ridge on the engine block valley cover around the rear bank knock sensor. DO NOT form a complete circle. Leave the rear section open as shown. 7. From the underside of the intake manifold, completely remove the rear intake manifold seal (foam material). 8. Install the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 2365 For vehicles repaired under warranty, use the table as shown DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set Knock Sensor: All Technical Service Bulletins Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-023A Date: June, 2002 TECHNICAL Subject: Audible Spark Knock (Detonation), MIL Illuminated, DTC P0332 Set (Replace Rear Bank Knock Sensor and RTV Area Around Sensor) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird with 5.7L Engine (VIN G - RPO LS1) 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalance 1999-2002 GMC Sierra, Yukon, Yukon XL 2002 Cadillac Escalade, Escalade EXT with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, N, U - RPOS LR4, LM7, L59, L09, L04) This bulletin is being revised to add Cadillac Escalade and Cadillac Escalade EXT to the Models. Please discard Corporate Bulletin Number 02-06-04-023 (Section 6 - Engine/Propulsion System). Condition Some customers may comment on a mild to severe engine ping (commonly referred to as spark knock), usually worse during acceleration and/or an illuminated MIL. Upon investigation, the technician may find DTC P0332 set. Cause This condition may be the result of corrosion of the rear bank knock sensor due to water intrusion into the sensor cavity. This condition is more apparent on vehicles in which customers frequently wash the engine compartment. Correction Replace the rear bank knock sensor and build a dam (wall) around the sensor using RTV to divert water away from the sensor. Use the procedure and part number listed. 1. Remove the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. 2. Remove the wiring harness assembly from the knock sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 2371 3. Remove the rear bank knock sensor. 4. Install the new rear bank knock sensor. Tighten Tighten the knock sensor to 20 N.m (15 lb ft). 5. Install the wiring harness assembly to the knock sensor. 6. Apply a bead of RTV silicone sealant approximately 9 mm (3/8 in) wide and 6 mm (1/4 in) high along the outside edge of the ridge on the engine block valley cover around the rear bank knock sensor. DO NOT form a complete circle. Leave the rear section open as shown. 7. From the underside of the intake manifold, completely remove the rear intake manifold seal (foam material). 8. Install the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 2372 For vehicles repaired under warranty, use the table as shown DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Page 2373 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2376 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2377 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2378 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2379 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2380 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2381 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2382 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2383 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2384 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2385 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2386 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2387 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2388 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2389 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2390 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2391 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2392 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2393 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2394 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2395 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2396 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2397 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2398 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2399 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2400 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2401 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2402 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2403 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2404 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2405 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2406 Knock Sensor (KS) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2407 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: ^ The broadband single wire sensor ^ The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: ^ All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. ^ The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near Top Dead Center (TDC) of the firing stroke. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2408 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Remove the knock sensor wiring harness assembly. 3. Remove the knock sensor (KS). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2409 1. Install the knock sensor. Tighten Torque the sensor to 20 N.m (15 lb ft). 2. Install the knock sensor wiring harness assembly. 3. Install the intake manifold. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations Air Bag Deactivation Switch: Component Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations > Page 2415 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations > Page 2416 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 2417 Inflatable Restraint IP Module Disable Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Inflatable Restraint IP module Disable Switch Indicator Air Bag Deactivation Switch: Description and Operation Inflatable Restraint IP module Disable Switch Indicator The Instrument Panel (IP) module disable switch ON/OFF indicator is an LED located in a position that can been viewed by the occupants in the front seats. The location varies depending on the vehicle. When the IP module disable switch is in the disable position, the IP module disable switch indicator illuminates. When the IP module disable switch is in the enable position, the IP module disable switch indicator is not illuminated. The IP module disable switch indicator will dim to a lower intensity when the headlamp switch is turned ON. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Inflatable Restraint IP module Disable Switch Indicator > Page 2420 Air Bag Deactivation Switch: Description and Operation Inflatable Restraint IP Module Disable Switch The Instrument Panel (IP) module disable switch is a manual 2-position key switch located inside the vehicle. The IP module disable switch allows the vehicle operator the ability to enable or disable the IP module (passenger frontal air bag). The vehicle operator must disable the IP module if a rear-facing child seat is installed in the front passenger seat. The IP module disable switch interfaces with the Sensing And Diagnostic Module (SDM) to request the enabling or disabling of the IP module. The occupants are notified of the enabling or disabling of the IP module via the IP module disable switch ON/OFF indicator located in the IP module disable switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Page 2421 Air Bag Deactivation Switch: Service and Repair INFLATABLE RESTRAINT IP MODULE DISABLE SWITCH REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the instrument panel trim bezel. 3. Remove the IP module switch from the lower right opening of the switch plate panel. 4. Disconnect the IP module switch electrical connector. INSTALLATION PROCEDURE 1. Connect the IP module switch electrical connector. 2. Install the IP module switch into the lower right opening of the switch plate panel. 3. Install the instrument panel trim bezel. 4. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Fastener Tightening Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Inflatable Restraint Front End Discriminating Sensors Impact Sensor: Locations Inflatable Restraint Front End Discriminating Sensors Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Inflatable Restraint Front End Discriminating Sensors > Page 2427 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Inflatable Restraint Front End Discriminating Sensors > Page 2428 Impact Sensor: Locations Inflatable Restraint Side Impact Sensors Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Inflatable Restraint Front End Discriminating Sensors > Page 2429 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Discriminating Sensor - 10/20 Sensor Inflatable Restraint Front End Discriminating Sensor - 10/20 Series Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Discriminating Sensor - 10/20 Sensor > Page 2432 Inflatable Restraint Electronic Frontal Sensor (EFS) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Discriminating Sensor - 10/20 Sensor > Page 2433 Impact Sensor: Diagrams Inflatable Restraint Side Impact Sensor (SIS) Inflatable Restraint Side Impact Sensor (SIS) - Left Inflatable Restraint Side Impact Sensor (SIS) - Right Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Technician Safety Information Impact Sensor: Technician Safety Information CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Technician Safety Information > Page 2436 Impact Sensor: Vehicle Damage Warnings CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Inflatable Restraint Front End Discriminating Sensor Impact Sensor: Description and Operation Inflatable Restraint Front End Discriminating Sensor The front end discriminating sensor is equipped on some vehicles to supplement SIR system performance. The discriminating sensor is an electro-mechanical sensor and is not part of the deployment loops, but instead provides an input to the SDM. The SDM uses the input from the discriminating sensor to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Inflatable Restraint Front End Discriminating Sensor > Page 2439 Impact Sensor: Description and Operation Inflatable Restraint Electronic Frontal Sensor (EFS) The Electronic Frontal Sensor (EFS) is equipped on some vehicles to supplement SIR system performance. The EFS is an electronic sensor (accelerometer) and is not part of the deployment loops, but instead provides an input to the SDM. The EFS can assists in determining the severity of some frontal collisions. The SDM contains a microprocessor that performs calculations using the measured accelerations. The SDM compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the frontal deployment loops deploying the frontal air bags. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Inflatable Restraint Front End Discriminating Sensor > Page 2440 Impact Sensor: Description and Operation Inflatable Restraint Side Impact Sensor The Side Impact Sensor (SIS) contains a sensing device (accelerometer) which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant air bag deployment. The SIB is not part of the deployment loop, but instead provides an input to the SDM. The SDM contains a microprocessor that performs calculations using the measured accelerations. The SDM compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the side deployment loops deploying the side air bags. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Replacement Impact Sensor: Service and Repair Front End Discriminating Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. 2. Remove the engine protection shield (if equipped). 3. Remove the connector position assurance (CPA) from the inflatable restraint front end discriminating sensor harness connector. 4. Disconnect the inflatable restraint front end discriminating sensor harness connector from the sensor. 5. Remove the mounting fasteners. 6. Remove the inflatable restraint front end discriminating sensor from the vehicle. IMPORTANT: The following procedure should be utilized in the event that the sensor mounting holes or fasteners are damaged to the extent that the sensor may no longer be properly mounted. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Replacement > Page 2443 7. Perform the following steps in order to complete the fastener repair: 7.1. Remove and discard the improperly installed fastener. 7.2. Chisel off the damaged weld nut. 7.3. Condition the front end lower tie surface where the new weld nut is to be installed. 7.4. Install the new weld nut (GM P/N 11514034) or equivalent into position. 7.5. Migweld the new weld nut to the front end lower tie surface in the correct location. 7.6. Use the new fastener (GM P/N 11515926) or equivalent. INSTALLATION PROCEDURE CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. 1. Install the inflatable restraint front end discriminating sensor to the front end lower tie surface. Make sure the arrow is pointing toward the front of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Replacement > Page 2444 2. Install the inflatable restraint front end discriminating sensor mounting fasteners. Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Connect the inflatable restraint front end discriminating sensor harness connector to the sensor. 4. Install the connector position assurance (CPA) to the inflatable restraint front end discriminating sensor harness connector. 5. Install the engine protection shield (if equipped). 6. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Replacement > Page 2445 Impact Sensor: Service and Repair Side Impact Sensor Replacement REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the front door trim panel. 3. Loosen the 2 inflatable restraint side impact sensor fasteners (2). 4. Remove the inflatable restraint side impact sensor (1) from the door (4). 5. Remove the connector position assurance (CPA) (3) and disconnect the inflatable restraint side impact sensor yellow 2-way harness connector (5). INSTALLATION PROCEDURE 1. Connect the inflatable restraint side impact sensor yellow 2-way harness connector (5) to the inflatable restraint side impact sensor (1). 2. Install the connector position assurance (CPA) (3) to the inflatable restraint side impact sensor yellow 2-way connector (5). 3. Install the inflatable restraint side impact sensor (1) to the door (4). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the fasteners (2) to the inflatable restraint side impact sensor (1). Tighten Use only hand tools in order to tighten the fasteners to 10 N.m (89 lb in). 5. Install the door trim panel. 6. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Locations View In the seat belt buckle Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 2449 Seat Belt Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Steering Wheel Speed/Position Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Steering Wheel Speed/Position Sensor - W/ RTD Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Steering Wheel Speed/Position Sensor - W/ RTD > Page 2467 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Page 2468 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Removal Procedure 1. Set the front wheels in the straight-ahead position. Set the steering wheel in the LOCKED position. 2. Disable the Supplemental Inflatable Restraint (SIR). 3. Remove the nut and the bolt (1) from the upper intermediate shaft connection and slide the intermediate steering shaft down. 4. Remove the position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. Important: Do not apply force to the sensor and the bearing in a sideways direction. 5. Remove the position sensor and bearing assembly from the steering column jacket by pulling the assembly straight out. 6. Remove the position sensor from the clips in the bearing assembly. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Page 2469 1. Install the position sensor into the bearing assembly. Important: Do not apply force to the sensor and the bearing in a sideways direction. 2. Install the bearing into the steering column jacket. 2.1. Align the notches on the bearing and the column jacket. 2.2. Seat the bearing fulling into the jacket. 3. Connect the position sensor connector. Notice: Refer to Fastener Notice in Service Precautions. 4. Slide the shaft up to install the bolt and the nut (1) to the upper intermediate shaft to steering column connection. Tighten the upper intermediate shaft connection to 47 Nm (35 ft. lbs.). 5. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering Revised Service Procedures Steering Column Position Sensor: Technical Service Bulletins Steering - Revised Service Procedures Bulletin No.: 03-02-36-002 Date: July 30, 2003 SERVICE MANUAL UPDATE Subject: Revised Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Procedure and Steering Wheel Position Sensor Centering Procedure Models: 1998-2003 Buick LeSabre, Park Avenue 1998-2003 Cadillac DeVille, Seville 2003 Cadillac CTS 1998-2003 Chevrolet Corvette 1998 Oldsmobile Achieva 1998-2002 Oldsmobile Intrigue 1998-2003 Oldsmobile Aurora 1999-2003 Oldsmobile Alero 1998-2003 Pontiac Bonneville, Grand Am 1998-2000 Chevrolet C/K Pickup Models 1998-2003 Chevrolet Suburban, Tahoe 1999-2003 Chevrolet Silverado 2002-2003 Chevrolet Avalanche 1998-1999 GMC Suburban 1998-2000 GMC C/K Pickup Models 1998-2003 GMC Yukon 1999-2003 GMC Sierra 2000-2003 GMC Yukon Denali, Yukon XL 2003 GMC Sierra Denali This bulletin is being issued to revise the Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement procedure in the Variable Effort Steering (1998-2001 model years) or Steering Wheel and Column (2002-2003 model years) and add the Steering Wheel Position Sensor Centering procedure in the Steering Wheel and Column sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Removal Procedure Caution: Refer to SIR Caution in Cautions and Notices. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. 2. Remove the steering column from the vehicle. Refer to Steering Column Replacement. 3. Remove the following from the steering shaft: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering Revised Service Procedures > Page 2474 3.1. steering shaft seal (7) 3.2. sensor retainer (6) 3.3. steering wheel position sensor (5), refer to Steering Wheel Position Sensor Centering. 3.4. 2 lower spring retainers (4) 3.5. lower bearing spring (3) 3.6. lower bearing seat (2) 3.7. adapter and bearing assembly (1) Installation Procedure 1. Install the following onto the steering shaft: 1.1. adapter and bearing assembly (1) 1.2. lower bearing seat (2) 1.3. lower bearing spring (3) 1.4. 2 lower spring retainers (4) 1.5. steering wheel position sensor (5) refer to Steering Wheel Position Sensor Centering. 1.6. sensor retainer (6) 1.7. steering shaft seal (7) 1.8. Enable the SIR system. Refer to in SIR. 2. Install the steering column to the vehicle. Refer to Steering Column Replacement. 3. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations below BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering Revised Service Procedures > Page 2475 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin (note location of the pin hole) ^ A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering Revised Service Procedures > Page 2476 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation section. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering Revised Service Procedures > Page 2477 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation section. 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation section. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering Revised Service Procedures > Page 2478 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin (note location of the pin hole) ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly. ^ A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering Revised Service Procedures > Page 2479 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats(1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering Revised Service Procedures > Page 2480 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering Revised Service Procedures > Page 2481 Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 2482 Steering Column Position Sensor: Service and Repair This article has been updated with TSB# 03-02-36-002 REVISED STEERING WHEEL POSITION SENSOR OR STEERING SHAFT LOWER BEARING REPLACEMENT PROCEDURE AND STEERING WHEEL POSITION SENSOR CENTERING PROCEDURE STEERING WHEEL POSITION SENSOR OR STEERING SHAFT LOWER BEARING REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Cautions and Notices. 1. Disable the SIR system. 2. Remove the steering column from the vehicle. 3. Remove the following from the steering shaft: A. steering shaft seal (7) B. sensor retainer (6) C. steering wheel position sensor (5), refer to Steering Wheel Position Sensor Centering. D. two lower spring retainers (4) E. lower bearing spring (3) F. lower bearing seat (2) G. adapter and bearing assembly (1) INSTALLATION PROCEDURE 1. Install the following onto the steering shaft: A. adapter and bearing assembly (1) B. lower bearing seat (2) C. lower bearing spring (3) D. 2 lower spring retainers (4) E. steering wheel position sensor (5) refer to Steering Wheel Position Sensor Centering. F. sensor retainer (6) G. steering shaft seal (7) H. Enable the SIR system. 2. Install the steering column to the vehicle. 3. Enable the SIR system. STEERING WHEEL POSITION SENSOR CENTERING REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 2483 IMPORTANT: Identify the type of steering wheel position sensor from the illustrations below BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. IMPORTANT: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin (note location of the pin hole) ^ A flush rotor flange cuff (4) IMPORTANT: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation section. 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 2484 ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation section. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation section. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation section. 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin (note location of the pin hole) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 2485 ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation section. INSTALLATION PROCEDURE IMPORTANT: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin (note location of the pin hole) ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly. ^ A view of the inside of the connector IMPORTANT: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT: If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 2486 ^ An alignment tab (2) for installing into the adapter and bearing assembly. IMPORTANT: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT: If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. IMPORTANT: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT:If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. IMPORTANT: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT:If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 2487 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. IMPORTANT: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT: If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications Ride Height Sensor: Specifications Front Position Sensor Link Bracket Bolt ................................................................................................................................................. 9 Nm (80 inch lbs.) Front Position Sensor Mounting Bolt .................................................................................................................................................. 12 Nm (106 inch lbs.) Rear Position Sensor Link Bracket Bolt ................................................................................................................................................... 25 Nm (18 ft. lbs.) Rear Position Sensor Mounting Bolt ................................................................................................................................................... 12 Nm (106 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Diagrams > LF Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Diagrams > LF > Page 2494 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Diagrams > LF > Page 2495 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Diagrams > LF > Page 2496 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Front Position Sensor Link Assembly Replacement - Electronic Suspension Ride Height Sensor: Service and Repair Front Position Sensor Link Assembly Replacement Electronic Suspension Front Position Sensor Link Assembly Replacement - Electronic Suspension Tools Required ^ J38185 Spring Hose Clamp Pliers Removal Procedure Important: Do not attempt to pry the link rod from the Real Time Damping (RTD) ball stud. If the link rod needs to be replaced or disconnected you must use the following procedure. 1. Remove the RTD sensor from the vehicle. 2. While supporting the sensor lever by hand, twist the link rod to remove it from the ball stud. 3. Remove the link rod from the mounting bracket ball stud. Installation Procedure 1. Using the J38185 install to link rod to the ball stud on the sensor lever and the mounting bracket. 2. Install the RTD sensor to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Front Position Sensor Link Assembly Replacement - Electronic Suspension > Page 2499 Ride Height Sensor: Service and Repair Rear Position Sensor Link Assembly Replacement Electronic Suspension Rear Position Sensor Link Assembly Replacement - Electronic Suspension Tools Required ^ J38185 Spring Hose Clamp Pliers Removal Procedure Important: Do not attempt to pry the link rod from the Real Time Damping (RTD) ball stud. If the link rod needs to be replaced or disconnected you must use the following procedure. 1. Remove the RTD sensor from the vehicle. 2. While supporting the sensor lever by hand, twist the link rod to remove it from the ball stud. 3. Remove the link rod from the frame bracket ball stud. Installation Procedure 1. Using the J38185 install to link rod to the ball stud on the sensor lever and the frame bracket. 2. Install the RTD sensor to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Steering Wheel Speed/Position Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Steering Wheel Speed/Position Sensor - W/ RTD Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Steering Wheel Speed/Position Sensor - W/ RTD > Page 2505 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Page 2506 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Removal Procedure 1. Set the front wheels in the straight-ahead position. Set the steering wheel in the LOCKED position. 2. Disable the Supplemental Inflatable Restraint (SIR). 3. Remove the nut and the bolt (1) from the upper intermediate shaft connection and slide the intermediate steering shaft down. 4. Remove the position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. Important: Do not apply force to the sensor and the bearing in a sideways direction. 5. Remove the position sensor and bearing assembly from the steering column jacket by pulling the assembly straight out. 6. Remove the position sensor from the clips in the bearing assembly. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Page 2507 1. Install the position sensor into the bearing assembly. Important: Do not apply force to the sensor and the bearing in a sideways direction. 2. Install the bearing into the steering column jacket. 2.1. Align the notches on the bearing and the column jacket. 2.2. Seat the bearing fulling into the jacket. 3. Connect the position sensor connector. Notice: Refer to Fastener Notice in Service Precautions. 4. Slide the shaft up to install the bolt and the nut (1) to the upper intermediate shaft to steering column connection. Tighten the upper intermediate shaft connection to 47 Nm (35 ft. lbs.). 5. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Control Pressure Sensor/Switch > Component Information > Service and Repair Suspension Control Pressure Sensor/Switch: Service and Repair "For information regarding this component please refer to air dryer suspension control service and repair" Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications 4L60-E Transmission Fluid Pressure Manual Valve Position Switch to Valve ................................................. ................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E A/T Fluid Pressure Manual Valve Position Switch Connector, Wiring Harness Side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E > Page 2523 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 2524 Fluid Pressure Sensor/Switch: Service and Repair For information relating to service of this component please refer to Valve Body; Service And Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Transmission Mode Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 2529 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 2530 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for voltage through the body wiring harness junction block. 7. This step tests for ground integrity at the splice pack. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 2531 Transmission Mode Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 2532 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 2533 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for voltage through the body wiring harness junction block. 7. This step tests for ground integrity at the splice pack. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 4L60-E Park/Neutral Position Switch Screw .................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E > Page 2539 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E Transmission Position Switch/Sensor: Adjustments 4L60-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E > Page 2542 Transmission Position Switch/Sensor: Adjustments 4L80-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E Transmission Position Switch/Sensor: Service and Repair 4L60-E Park Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 2545 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 2546 Transmission Position Switch/Sensor: Service and Repair 4L80-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 2547 4. Position the tool J41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications 4L60-E Speed Sensor Retainer Bolt ................................................................................................................................................. 10.5-13.5 Nm (7.7-10 ft. lbs.) 4L80-E Speed Sensor and Bracket Assembly to Case .................................................................................................................................... 11 Nm (97 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E Vehicle Speed Sensor (VSS) Sensor Connector, Wiring Harness Side (4L60-E) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E > Page 2553 Transmission Speed Sensor: Diagrams 4L80-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E Transmission Speed Sensor: Service and Repair 4L60-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 2556 Transmission Speed Sensor: Service and Repair 4L80-E Vehicle Speed Sensor (VSS) Replacement- Input Vehicle Speed Sensor (VSS) Replacement- Input Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor (1) electrical connector. 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1) and the bracket assembly from the case. 5. Inspect the vehicle speed sensor assembly (1) for any evidence of damage. Installation Procedure. 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1) and the bracket assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector. 5. Lower the vehicle. Vehicle Speed Sensor (VSS) Replacement-Output Vehicle Speed Sensor (VSS) Replacement-Output Removal Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 2557 1. Raise the vehicle. Refer to Vehicle Lifting. Important: This procedure is for 2WD vehicles. If the vehicle is equipped with 4WD, the output speed sensor is located on the transfer case. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2) and the bracket assembly from the case. 5. Inspect the output speed sensor assembly (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2) and the bracket assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the output speed sensor electrical connector. 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Transmission Fluid Temperature (TFT) Sensor Connector, Wiring Harness Side (4L80-E) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 02-04-21-004 > Apr > 02 > Transfer Case Switch - `Service 4WD' Indicator ON Four Wheel Drive Selector Switch: Customer Interest Transfer Case Switch - `Service 4WD' Indicator ON File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-004 Date: April, 2002 TECHNICAL Subject: " "Service 4WD" Indicator Illuminated, DTC B2725 Set (Replace Transfer Case Shift Control Switch) Models: 1999-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Avalanche, Suburban, Tahoe, Yukon, Yukon XL) with Four Wheel Drive and NVG 236/246 Transfer Case (RPO NP8) Condition Some customers may comment on the Service 4WD indicator illuminating. Upon investigation, the technician may find DTC B2725 set. Cause The condition may be due to a intermittent fault in the transfer case shift control switch. Correction Important: The transfer case shift control module should not need replacement. DO NOT replace P/N 15749703 unless diagnosis points to the module as the malfunction. Replace the transfer case shift control switch using published Service Information procedures. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 02-04-21-004 > Apr > 02 > Transfer Case Switch `Service 4WD' Indicator ON Four Wheel Drive Selector Switch: All Technical Service Bulletins Transfer Case Switch - `Service 4WD' Indicator ON File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-004 Date: April, 2002 TECHNICAL Subject: " "Service 4WD" Indicator Illuminated, DTC B2725 Set (Replace Transfer Case Shift Control Switch) Models: 1999-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Avalanche, Suburban, Tahoe, Yukon, Yukon XL) with Four Wheel Drive and NVG 236/246 Transfer Case (RPO NP8) Condition Some customers may comment on the Service 4WD indicator illuminating. Upon investigation, the technician may find DTC B2725 set. Cause The condition may be due to a intermittent fault in the transfer case shift control switch. Correction Important: The transfer case shift control module should not need replacement. DO NOT replace P/N 15749703 unless diagnosis points to the module as the malfunction. Replace the transfer case shift control switch using published Service Information procedures. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Transfer Case Shift Control Switch - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Transfer Case Shift Control Switch - C1 > Page 2577 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 2578 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel bezel trim piece. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. 1. Install the transfer case driver control switch into the instrument panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 2579 2. Install the instrument panel trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Page 2584 Speed Sensor: Specifications Transfer Case Speed Sensors ............................................................................................................ ........................................................ 15 Nm (11 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 2587 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) Speed Sensor: Service and Repair NVG 149-NP (One Speed Automatic) Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the electrical connector from the speed sensor. 3. Remove the speed sensor from the transfer case. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 2590 1. Install the right rear speed sensor into the transfer case. ^ Tighten the right rear speed sensor to 31 Nm (23 ft. lbs.). 2. Install the electrical connector to the speed sensor. 3. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 2591 Speed Sensor: Service and Repair NVG 236/246-NP8 (Two Speed Automatic) Transfer Case Speed Sensor Replacement (Front) Transfer Case Speed Sensor Replacement (Front) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield. 3. Remove the transfer case front speed sensor electrical connector. 4. Remove the transfer case front speed sensor. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 2592 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case front speed sensor into the transfer case. ^ Tighten the transfer case front speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case front speed sensor electrical connector. 3. Install the transfer case shield. 4. Lower the vehicle. Refer to Vehicle Lifting. Transfer Case Speed Sensor Replacement (Right Rear) Transfer Case Speed Sensor Replacement (Right Rear) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 2593 2. Remove the transfer case right rear electrical connector. 3. Remove the transfer case right rear speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case right rear speed sensor to the transfer case. ^ Tighten the transfer case right rear speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case right rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Transfer Case Speed Sensor Replacement (Left Rear) Transfer Case Speed Sensor Replacement (Left Rear) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case left rear speed sensor electrical connector. 3. Remove the transfer case left rear speed sensor. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 2594 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case left rear speed sensor into the transfer case. ^ Tighten the transfer case left rear speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case left rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2601 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2602 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2603 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2604 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2605 Power Window Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2606 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2607 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2608 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2609 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2610 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2611 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2612 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2613 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2614 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2615 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2616 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2617 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2618 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2619 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2620 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2621 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2622 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2623 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2624 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2625 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2626 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2627 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2628 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2629 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2630 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2631 Power Window Switch: Connector Views Window Switch - LR/RR Window/Door Lock Switch - Driver (Except Base) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2632 Window/Door Lock Switch - Driver Connector C1 (Except Base) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2633 Window/Door Lock Switch - Driver Connector C2 (Except Base) For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2634 Window/Door Lock Switch - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement Power Window Switch: Service and Repair Power Window Switch Replacement REMOVAL PROCEDURE 1. Remove the power accessory switch panel. 2. Disconnect the power window switch electrical connector. 3. Remove the screws from the window switch. 4. Remove the switch from the switch panel by lifting the rear of the switch and sliding the switch out from the switch panel. INSTALLATION PROCEDURE 1. Install the switch to the switch panel sliding the front tabs in first. Rock the switch down in order to seat the switch completely. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the window switch. Tighten Tighten the window switch screws to 2 N.m (18 lb in). 3. Connect the electrical connector to the window switch. 4. Install the power accessory switch panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement > Page 2637 Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door REMOVAL PROCEDURE 1. Use a small flat-bladed tool in order to carefully pry the door power window switch from the door trim panel. 2. Disconnect the electrical connector from the switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the switch. 2. Install the switch to the door trim panel by pressing the switch into place until fully seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams Rear Wiper/Washer Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 2645 Rear Wiper/Washer And Fog Lamp Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 2649 Rear Wiper/Washer And Fog Lamp Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2655 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2656 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2657 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2658 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2659 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2660 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2661 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2662 Alignment: Technical Service Bulletins Steering/Suspension - Revised Caster/Camber Adjustment Info - Revised Front Caster and Camber Adjustment Procedure # 02-03-07-002A - (Mar 24, 2005) Models: 1999-2000 Cadillac Escalade 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Express, Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999 GMC Suburban 1999-2005 GMC Savana, Sierra, Yukon, Yukon XL, Yukon XL Denali This bulletin is being revised to add model years and clarify the information. Please discard Corporate Bulletin Number 02-03-07-002 (Section 03 - Suspension). When performing a wheel alignment on any of the above vehicles, please refer to the Front Caster and Camber Adjustment Procedure in SI before contacting the GM Technical Assistance Center (TAC) with issues concerning adjustments, caster out-of-spec, etc. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Ride/Trim Height Inspection Procedure Alignment: Specifications Ride/Trim Height Inspection Procedure Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: 1. Set the tire pressures to the pressure shown on the certification label. 2. Check the fuel level. Add additional weight if necessary to simulate a full tank. 3. Make sure the rear compartment is empty except for the spare tire. 4. Make sure the vehicle is on a level surface, such as an alignment rack. 5. Close the doors. 6. Close the hood. 7. All dimensions are measured vertical to the ground. Trim heights should be within 13 mm (0.5 inch) to be considered correct. Z Height Measurement Important: K models only the Z height must be adjusted before the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use an adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Lift the front bumper of the vehicle up about 38 mm (1.5 inch). 2. Gently remove your hands. 3. Allow the vehicle to settle into position. 4. Repeat this jouncing operation 2 more times for a total of 3 times. 5. Measure from the pivot bolt center line (3) down to the lower corner (5) of the lower ball joint (1) in order to obtain the Z height measurement (4). 6. Push the front bumper of the vehicle down about 38 mm (1.5 inch). 7. Gently remove your hands. 8. Allow the vehicle to rise. 9. Repeat the operation for a total of 3 times. 10. Measure the Z dimension. 11. The true Z height dimension number is the average of the high and the low measurements. Z Height Adjustment Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Ride/Trim Height Inspection Procedure > Page 2665 1. For vehicles equipped with a torsion bar suspension turn the bolt (1) that contacts the torsion arm clockwise to raise the and counterclockwise to lower the height adjustment. One revolution of the bolt (1) into the nut increases the Z height by approximately 6.0 mm (0.2 inch). 2. For vehicles without torsion bars, replace damaged or worn components as necessary. D Height Measurement The D height dimension measurement determines the proper rear end ride height. There is no adjustment procedure. Repair may require replacement of suspension components. 1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 inch). 2. Gently remove your hands. Allow the vehicle to settle into position. 3. Repeat the jouncing operation 2 more times for a total of 3 times. 4. Measure the D height by measuring the distance between the bumper bracket and the top of the rear axle tube. 5. Push the rear bumper downward to 38 mm (1.5 inch). 6. Gently remove your hands. Allow the vehicle to settle into position. 7. Repeat the jouncing operation 2 more times for a total of 3 times. 8. Measure the D height dimension. 9. The true D height dimension number is the average of the high and the low measurements. 10. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging front suspension ^ Sagging rear leaf/coil springs ^ Worn rear suspension components, such as leaf spring bushings ^ Improper tire inflation ^ Improper weight distribution ^ Collision damage Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Ride/Trim Height Inspection Procedure > Page 2666 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Ride/Trim Height Inspection Procedure > Page 2667 Alignment: Specifications Wheel Alignment Specifications Alignment Wheel Alignment Specifications Fastener Tightening Specifications Trim Height Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2668 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear and is not adjustable on this vehicle. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2669 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Lead/pull is the deviation of the vehicle from a straight path, on a level road, without hand pressure on the steering wheel. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Uneven brake adjustment ^ Wheel alignment The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2670 Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Alignment: Service and Repair Trim Height Inspection Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: 1. Set the tire pressures to the pressure shown on the certification label. 2. Check the fuel level. Add additional weight if necessary to simulate a full tank. 3. Make sure the rear compartment is empty except for the spare tire. 4. Make sure the vehicle is on a level surface, such as an alignment rack. 5. Close the doors. 6. Close the hood. 7. All dimensions are measured vertical to the ground. Trim heights should be within 13 mm (0.5 inch) to be considered correct. Z Height Measurement Important: K models only the Z height must be adjusted before the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use an adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Lift the front bumper of the vehicle up about 38 mm (1.5 inch). 2. Gently remove your hands. 3. Allow the vehicle to settle into position. 4. Repeat this jouncing operation 2 more times for a total of 3 times. 5. Measure from the pivot bolt center line (3) down to the lower corner (5) of the lower ball joint (1) in order to obtain the Z height measurement (4). 6. Push the front bumper of the vehicle down about 38 mm (1.5 inch). 7. Gently remove your hands. 8. Allow the vehicle to rise. 9. Repeat the operation for a total of 3 times. 10. Measure the Z dimension. 11. The true Z height dimension number is the average of the high and the low measurements. Z Height Adjustment Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 2673 1. For vehicles equipped with a torsion bar suspension turn the bolt (1) that contacts the torsion arm clockwise to raise the and counterclockwise to lower the height adjustment. One revolution of the bolt (1) into the nut increases the Z height by approximately 6.0 mm (0.2 inch). 2. For vehicles without torsion bars, replace damaged or worn components as necessary. D Height Measurement The D height dimension measurement determines the proper rear end ride height. There is no adjustment procedure. Repair may require replacement of suspension components. 1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 inch). 2. Gently remove your hands. Allow the vehicle to settle into position. 3. Repeat the jouncing operation 2 more times for a total of 3 times. 4. Measure the D height by measuring the distance between the bumper bracket and the top of the rear axle tube. 5. Push the rear bumper downward to 38 mm (1.5 inch). 6. Gently remove your hands. Allow the vehicle to settle into position. 7. Repeat the jouncing operation 2 more times for a total of 3 times. 8. Measure the D height dimension. 9. The true D height dimension number is the average of the high and the low measurements. 10. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging front suspension ^ Sagging rear leaf/coil springs ^ Worn rear suspension components, such as leaf spring bushings ^ Improper tire inflation ^ Improper weight distribution ^ Collision damage Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 2674 Alignment: Service and Repair Measuring Wheel Alignment Measuring Wheel Alignment Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. Refer to Tire Inflation Pressure Specifications and Tire Diagnosis - Irregular or Premature Wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. ^ Inspect the vehicle trim height. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 2675 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Front Caster and Camber Adjustment 1. Determine if the vehicle is relative to frame or relative to ground. If caster is relative to frame, the caster values must be compensated for the measured frame angle. To determine the frame angle use a digital protractor or equivalent. 2. Frame angle is positive when higher in the rear. Measure both sides of the frame and take an average from those measurements. Then add the average frame angle to the caster reading obtained in step 5 of this procedure when making adjustments. 3. Frame angle is negative when lower in the rear. Measure both sides of the frame and take an average from the measurements. Then subtract the average frame angle from the caster reading obtained in step 5 of this procedure when making adjustments. 4. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Important: Before adjusting the caster and camber angles, jounce the front bumper three times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. 5. For an accurate reading, do not push or pull on the tires during the alignment process. 6. Determine the caster angle (2). Be sure to compensate for frame angle where required. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 2676 7. Determine the positive camber (2) or negative camber (3) angle. 8. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 9. Loosen the upper control arm cam adjustment bolts. Notice: Refer to Fastener Notice in Service Precautions. 10. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met. When the adjustments are complete, hold the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. Tighten the cam nuts to 190 Nm (140 ft. lbs.). 11. Verify that the caster and the camber are still within specifications. When the caster and camber are within specifications, adjust the toe. Front Wheel Toe Adjustment Front Toe Adjustment Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 2677 1. Loosen the jam nut on the tie rod (2). 2. Rotate the inner tie rod (1) to the required toe specification setting. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the jam nut on the tie rod. Tighten the tie rod jam to 68 Nm (50 ft. lbs.). 4. Check the toe seeing after tightening. 5. Re-adjust the toe setting if necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Measure with the Key On Engine Off with the fuel pump commanded ON. Vin (V,T,U) Fuel Pressure (gasoline) ..................................................................................................................... ................................................................. 55-62 psi Vin (Z) Fuel Pressure (ethanol) ....................................................................................................................... ................................................................. 48-54 psi These specifications are taken from the Fuel System Diagnosis. For complete testing of fuel pressures and volume see Fuel System Diagnosis, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE CAUTION: ^ Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. ^ Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 1. Install the fuel pressure gauge to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gauge in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gauge. 7. Inspect for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2684 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST DESCRIPTION Steps 1-2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2685 Steps 3-7 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2686 Steps 8-13 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2687 Steps 14-18 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2688 Steps 19-25 The numbers below refer to the step numbers on the diagnostic table. 2. This step verifies that the fuel pump is operating. 4. This step tests for an internal fuel leak. If the fuel pressure drops during this test, then an internal loss of pressure is indicated. 6. This step tests the fuel pressure regulator. The fuel pressure regulator is controlled by the engine vacuum. With the engine vacuum applied, the pressure should drop to the specified value. 9. This step inspects the fuel pressure regulator for a fuel leak from the vacuum port. If fuel leaks from the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator. 10. This step tests for a loss of fuel pressure between the fuel feed pipe shut-off adapter and the fuel pump. 11. This step tests for a leaking fuel injector or for a leaking fuel pressure regulator. If the fuel pressure remains constant during this test, the fuel injectors are not leaking fuel. 14. This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, there is a restriction in the fuel return pipe. 16. This step determines if the fuel pressure regulator or the fuel pump is the cause of the low fuel pressure. If the pressure rises above the specified value, the fuel pump is OK. 18. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Thoroughly inspect all fuel electrical circuits. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed ........................................................................................................................................... .............................................................. 500-700 rpm Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Restriction Indicator > Component Information > Description and Operation Air Cleaner Restriction Indicator: Description and Operation Air Cleaner Restriction Indicator The air cleaner restriction indicator is located on the air cleaner assembly between the air filter and the mass air flow (MAF) sensor. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2704 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2710 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2711 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake duct (2). 2. Disconnect the electrical connector from the mass air flow/intake air temperature (MAF/IAT) sensor. 3. Loosen the 4 fasteners (8) securing the air cleaner housing top cover (4). 4. Lift and rotate the top cover (4) of the air cleaner housing to gain access to the air filter element. 5. Lift out the air filter element (5). 6. Inspect the air filter element for dust, dirt, or water. Clean or replace the air filter element if required. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2712 1. Install the air filter element (5) into the air cleaner housing. 2. Rotate and install the top cover (4) to the air cleaner housing (6). 3. Insert the fasteners (8) to secure the top cover. 4. Connect the MAF/IAT electrical connector. 5. Install the intake duct. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE CAUTION: ^ Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. ^ Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 1. Install the fuel pressure gauge to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gauge in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gauge. 7. Inspect for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2718 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance Of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 2. Remove the engine sight shield. 3. Loosen the fuel filler cap in order to relieve the fuel tank vapor pressure. 4. Connect the J 34730-1A to the fuel pressure valve. 5. Install the bleed hose of the gauge into an approved container. 6. Open the valve on the gauge to bleed the system pressure. The fuel connections are now safe for servicing. 7. Drain any fuel remaining in the gauge into an approved container. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition System Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection Ignition Cable: Service and Repair Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: ^ Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. ^ Any signs of cracks or splits in the wires. ^ Inspect each boot for the following conditions: Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 2724 Ignition Cable: Service and Repair Spark Plug Wire Replacement REMOVAL PROCEDURE 1. Disconnect the spark plug wire at each spark plug. ^ Twist each spark plug 1/2 turn. ^ Pull only on the boot in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the ignition coil. ^ Twist each spark plug boot 1/2 turn. ^ Pull only on the boot in order to remove the wires from the ignition coil. SPARK PLUG WIRE LENGTH V8 Spark Plug Wire Length V8 ^ The Melco(R), square design, uses a spark plug wire (1) that is 145 mm (5.70 in) length cable seal to cable seal. ^ The Delphi(R), round design uses a spark plug wire (2) that is 110 mm (4.30 in) length cable seal to cable seal. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 2725 Ignition Coils ^ There are 2 different manufacturers for the ignition coils, the Melco(R) (1) square design, and the Delphi(R) (2) round design. These 2 coils use 2 different spark plug wire, and mounting brackets. ^ Melco(R), square design, coil mounting bracket (1). ^ Delphi(R), round design, coil mounting bracket (2). INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 2726 1. Install the spark plug wires at the ignition coil. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: ^ Push sideways on each boot in order to inspect the seating. ^ Reinstall any loose boot. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - New Spark Plugs & Gapping Info. Spark Plug: Technical Service Bulletins Ignition System - New Spark Plugs & Gapping Info. INFORMATION Bulletin No.: 03-06-04-060B Date: July 30 2008 Subject: Information on New Spark Plugs and Gapping Models Attention: Please disregard the Set Gap Per Vehicle Specification statement on the side of an ACOelco(R) Iridium Spark Plug Box. The statement will be removed from the boxes in the future. Supercede: This bulletin is being revised to add the Chevrolet SSR and the 2005 Pontiac GTO. Please discard Corporate Bulletin Number 03-06-04-060A (Section 06 - Engine/Propulsion System). ^ A new spark plug has been released for use in the above vehicles. The new spark plug has an Iridium tip instead of the current Platinum tip. Due to the different tip design the gap of the spark plug has also changed. ^ The new spark plug P/N 12571164 with AC Delco P/N 41-985 is gapped to 1.01 mm (0.040 in) when the spark plug is made. Notice: The spark plug gap is set during manufacturing and should not be changed or damage to the spark plug may result. Any new spark plug found to not be properly gapped should not be used. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2731 Spark Plug: Specifications This article has been updated with TSB #03-06-04-060B INFORMATION ON NEW SPARK PLUGS AND GAPPING SPARK PLUG GAP.............................................................................................................................. .................................................. 1.01 mm (0.040 in.) ^ A new spark plug has been released for use in the above vehicles. The new spark plug has an Iridium tip instead of the current Platinum tip. Due to the different tip design, the gap of the spark plug has also changed. ^ The new spark plug, P/N 12571164 with AC Delco P/N 41-985, is gapped to 1.01mm (0.040 inches) when the spark plug is made. Notice: The spark plug gap is set during manufacturing and should not be changed or damage to the spark plug may result. Any new spark plug found to not be properly gapped should not be used. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2732 Spark Plug: Application and ID AC Plug Type ...................................................................................................................................... ................................................................... 25171803 NGK Plug Type .................................................................................................................................... ................................................................. 12567759 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection Spark Plug: Service and Repair Spark Plug Inspection SPARK PLUG USAGE ^ Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. ^ Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION ^ Inspect the terminal P05 (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. ^ Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 2735 ^ Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). ^ Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. ^ A rattling sound indicates internal damage. ^ A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. ^ Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION ^ Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. ^ Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures ^ Leaking fuel injectors ^ Excessive fuel pressure ^ Restricted air filter element ^ Incorrect combustion Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 2736 - Reduced ignition system voltage output ^ Weak coils ^ Worn ignition wires ^ Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. ^ Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 2737 Spark Plug: Service and Repair Spark Plug Replacement REMOVAL PROCEDURE 1. Remove the spark plug wires. 2. Loosen each spark plug 1 or 2 turns. 3. Brush or air blast away any dirt from around the spark plugs. 4. Remove the spark plugs 1 at a time. Place each plug in a tray marked with the corresponding cylinder numbers. INSTALLATION PROCEDURE 1. Properly position each spark plug washer. 2. Inspect each spark plug gap. Adjust each plug as needed. Specification Spark plug gap: 1.52 mm (0.060 in) NOTE: Refer to Fastener Notice in Service Precautions. 3. Hand start the spark plugs in the corresponding cylinders. 4. Tighten the spark plugs. Tighten ^ For used heads tighten the spark plugs to 15 N.m (11 lb ft). ^ For new aluminum heads tighten the spark plugs to 20 N.m (15 lb ft). ^ For new iron heads, tighten the spark plugs to 30 N.m (22 lb ft). 5. Install the spark plug wires. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1035 x 70% = 725) (150 x 70% = 105). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Engine Compression Test (Electronic Throttle) Compression Check: Testing and Inspection Engine Compression Test (Electronic Throttle) Engine Compression Test (Electronic Throttle) 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gauge at zero and crank the engine through four compression strokes, four puffs. 8. Check the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml. (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Recheck the compression and record the reading. 10. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1035 x 70% = 725) (150 x 70% = 105). Normal-Compression builds up quickly and evenly to the specified compression for each cylinder. - Piston Rings Leaking-Compression is low on the first stroke. Then compression builds up with the following strokes but does not reach normal. Compression improves considerably when you add oil. - Valves Leaking-Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. - If two adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Engine Compression Test (Electronic Throttle) > Page 2743 Compression Check: Testing and Inspection Engine Compression Test (Mechanical Throttle) Engine Compression Test (Mechanical Throttle) 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Block the throttle plate wide open. 6. Start with the compression gauge at zero and crank the engine through four compression strokes, four puffs. 7. Make the compression check for each cylinder. Record the reading. 8. If a cylinder has low compression, inject approximately 15 ml. (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Recheck the compression and record the reading. 9. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1035 x 70% = 725) (150 x 70% = 105). Normal-Compression builds up quickly and evenly to the specified compression for each cylinder. - Piston Rings Leaking-Compression is low on the first stroke. Compression then builds up with the following strokes but does not reach normal. Compression improves considerably when you add oil. - Valves Leaking-Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. - If two adjacent cylinders have lower than normal compression and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 01-02-32-007 > Sep > 01 > Accessory Drive Belt - Whining Type Noise Drive Belt: Customer Interest Accessory Drive Belt - Whining Type Noise File In Section: 02 - Steering Bulletin No.: 01-02-32-007 Date: September, 2001 TECHNICAL Subject: Accessory Drive Belt Whine (Reposition Power Steering Pump Pulley) Models: 2001-02 Chevrolet and GMC C/K 1500 Series Utility Models (Tahoe, Suburban, Yukon, Yukon XL, Denali, Denali XL) Built at Janesville Assembly Plant (Plant Code J) from December, 2000 through July, 2001 Condition Some customers may comment on a whining-type noise that is audible in the vehicle's passenger compartment. This noise can typically be heard when the vehicle is idling and may vary in pitch as engine RPM is increased. Cause The power steering (PS) pump pulley may be positioned too far inboard on the PS pump. Correction Inspect the PS pump pulley for proper positioning on the PS pump shaft. If it is determined that the pulley is not even/flush with the end of the shaft (+/- 0.25 mm (0.010 in) following the applicable Service Manual procedure and using J 25034-C, reposition the PS pump pulley. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics Drive Belt: All Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 2760 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 2761 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 04-06-01-013 > Apr > 04 > Engine - Serpentine Drive Belt Wear Information Drive Belt: All Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 01-02-32-007 > Sep > 01 > Accessory Drive Belt - Whining Type Noise Drive Belt: All Technical Service Bulletins Accessory Drive Belt - Whining Type Noise File In Section: 02 - Steering Bulletin No.: 01-02-32-007 Date: September, 2001 TECHNICAL Subject: Accessory Drive Belt Whine (Reposition Power Steering Pump Pulley) Models: 2001-02 Chevrolet and GMC C/K 1500 Series Utility Models (Tahoe, Suburban, Yukon, Yukon XL, Denali, Denali XL) Built at Janesville Assembly Plant (Plant Code J) from December, 2000 through July, 2001 Condition Some customers may comment on a whining-type noise that is audible in the vehicle's passenger compartment. This noise can typically be heard when the vehicle is idling and may vary in pitch as engine RPM is increased. Cause The power steering (PS) pump pulley may be positioned too far inboard on the PS pump. Correction Inspect the PS pump pulley for proper positioning on the PS pump shaft. If it is determined that the pulley is not even/flush with the end of the shaft (+/- 0.25 mm (0.010 in) following the applicable Service Manual procedure and using J 25034-C, reposition the PS pump pulley. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics Drive Belt: All Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 2775 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 2776 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 04-06-01-013 > Apr > 04 > Engine - Serpentine Drive Belt Wear Information Drive Belt: All Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customers concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. It the engine is not making the noise do not proceed any further in this table. 3. The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2783 is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2784 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application. Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off. Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one or more grooves on a pulley(s). 3. The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys. 4. This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2785 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s). Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2786 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt(s) may be the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the fibs of the drive belt(s) will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt(s) does not have a smooth surface for proper operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2787 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customers concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. It the engine is not making the noise do not Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2788 proceed any further in this table. 3. The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application. Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off. Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one or more grooves on a pulley(s). 3. The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys. 4. This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2789 Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s). Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s). Drive Belt Rumbling Drive Belt Rumbling Diagnosis Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2790 Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt(s) may be the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the fibs of the drive belt(s) will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt(s) does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2791 Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body, or suspension component, or other item(s) on the vehicle may cause the squeal noise. If the squeal is intermittent, verify that it is not the accessory drive component(s) by varying their load(s), making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The squeal may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further in this table. 3. The squeal may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the squealing noise is related to the drive belt(s) or an accessory drive component. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. This test is to verify that an accessory drive component(s) does not have a seized bearing. With the belt(s) removed, test the bearings in the accessory drive component(s) for smooth operation. Also test the accessory drive component(s) with the engine operating by varying the load on the accessory drive component(s) to verify that the component(s) is operating properly. 5. This test is to verify that the drive belt(s) tensioner(s) are not operating properly. If the drive belt tensioner(s) are not operating properly, proper belt tension may not be achieved to keep the drive belt(s) from slipping which could cause a squealing noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner(s) from operating properly. Also if the incorrect length drive belt(s) was installed, it may not be routed correctly and may be turning an accessory drive component in the incorrect direction. 7. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 8. Inspect the accessory drive pulley(s) to verify that they are the correct diameter or width. Using a known good vehicle, compare the accessory drive pulleys. Drive Belt Vibration Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2792 Drive Belt Vibration Diagnosis Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components may have an affect on engine vibration. An overcharged air conditioning (A/C) system, a power steering system restriction, or the incorrect fluid, or an extra load placed on the generator are suggested items to inspect. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the vibration is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the vibration is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the drive belt(s). 6. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smooth operation. Inspect for a bent fan shaft or bent mounting flange. 9. Inspect the water pump drive shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known, good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put an extra strain on that accessory drive component causing it to vibrate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2793 Drive Belt Whine Drive Belt Whine Diagnosis Drive Belt Whine Diagnosis Diagnostic Aids The drive belt(s) will not cause the whine. If the whine is intermittent, verify that it is not the accessory drive component(s) by varying their loads, making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description The number(s) below refer to the step(s) in the diagnostic table. 3. This test is to verify that the whine is being caused by the accessory drive component(s). Remove the drive belt(s) and operate the engine for a few seconds this will verify if the whining noise is related to the accessory drive component. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. This inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper removal and installation procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Accessory Drive Belt Replacement Drive Belt: Service and Repair Accessory Drive Belt Replacement Drive Belt Replacement - Accessory Removal Procedure 1. Loosen the air cleaner outlet duct clamps at the following locations: - Throttle body - Mass airflow/intake air temperature (MAF/IAT) sensor 2. Remove the radiator inlet hose clip from the outlet duct. 3. Remove the air cleaner outlet duct. 4. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 5. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt. 6. Remove the belt from the pulleys and the drive belt tensioner. 7. Slowly release the tension on the drive belt tensioner. 8. Remove the breaker bar and socket and from the drive belt tensioner bolt. 9. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Accessory Drive Belt Replacement > Page 2796 1. Route the drive belt around all the pulleys except the idler pulley. 2. Install the breaker bar with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner. 4. Install the drive belt under the idler pulley. 5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner bolt. 7. Inspect the drive belt for proper installation and alignment. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. 8. Install the air cleaner outlet duct. 9. Install the radiator inlet hose clip to the outlet duct. Notice: Refer to Fastener Notice in Service Precautions. 10. Tighten the air cleaner outlet duct clamps at the following locations: - Throttle body - MAF/IAT sensor - Tighten the air cleaner outlet duct clamp screws to 7 Nm (62 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Accessory Drive Belt Replacement > Page 2797 Drive Belt: Service and Repair A/C Belt Drive Belt Replacement - Air Conditioning Removal Procedure 1. Remove the accessory drive belt. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the engine shield bolts. 4. Remove the engine shield. 5. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening. 6. Rotate the A/C belt tensioner clockwise in order to relieve tension on the belt. 7. Remove the A/C belt from the pulleys. 8. Slowly release the tension on the A/C belt tensioner. 9. Remove the ratchet from the A/C belt tensioner. 10. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Accessory Drive Belt Replacement > Page 2798 1. Install the A/C belt around the crankshaft balancer. 2. Install a ratchet into the A/C drive belt tensioner adapter opening 3. Rotate the A/C belt tensioner clockwise in order to relieve tension on the tensioner. 4. Install the A/C belt over the idler pulley. 5. Install the A/C belt around the A/C compressor pulley. 6. Slowly release the tension on the A/C belt tensioner. 7. Remove the ratchet from the A/C belt tensioner. 8. Inspect the A/C belt for proper installation and alignment. 9. Install the engine shield. Notice: Refer to Fastener Notice in Service Precautions. 10. Install the engine shield bolts. - Tighten the engine shield bolts to 20 Nm (15 ft. lbs.). 11. Lower the vehicle. 12. Install the accessory drive belt. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Restriction Indicator > Component Information > Description and Operation Air Cleaner Restriction Indicator: Description and Operation Air Cleaner Restriction Indicator The air cleaner restriction indicator is located on the air cleaner assembly between the air filter and the mass air flow (MAF) sensor. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON > Page 2812 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2818 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2819 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake duct (2). 2. Disconnect the electrical connector from the mass air flow/intake air temperature (MAF/IAT) sensor. 3. Loosen the 4 fasteners (8) securing the air cleaner housing top cover (4). 4. Lift and rotate the top cover (4) of the air cleaner housing to gain access to the air filter element. 5. Lift out the air filter element (5). 6. Inspect the air filter element for dust, dirt, or water. Clean or replace the air filter element if required. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2820 1. Install the air filter element (5) into the air cleaner housing. 2. Rotate and install the top cover (4) to the air cleaner housing (6). 3. Insert the fasteners (8) to secure the top cover. 4. Connect the MAF/IAT electrical connector. 5. Install the intake duct. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations > Page 2824 Cabin Air Filter: Service and Repair REMOVAL PROCEDURE 1. If equipped, remove the Instrument Panel (I/P) sound insulator. 2. Remove the filter access door screw. 3. Remove the filter access door (1) from the HVAC module. 4. Remove the passenger compartment air filter (2). INSTALLATION PROCEDURE 1. Install the passenger compartment air filter (2). 2. Install the filter access door (1) to the HVAC module. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the filter access door screw. Tighten Tighten The Screw to 1.6 Nm (14 lb in). 4. If equipped, install the I/P sound insulator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E Fluid Filter - A/T: Service and Repair 4L60-E Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining field. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E > Page 2829 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E > Page 2830 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan bolts. ^ Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E > Page 2831 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E > Page 2832 Fluid Filter - A/T: Service and Repair 4L80-E Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Remove the oil pan bolts. 5. Remove the oil pan. 6. Remove the gasket. 7. Remove the magnet. 8. Remove the oil filter. 9. Remove the filter neck seal. 10. The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. 11. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E > Page 2833 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan to the transmission with seventeen bolts. ^ Tighten the oil pan bolts to 11 Nm (97 inch lbs.). 6. Apply a small amount of sealant GM P/N 12346004 to the treads of the drain plug, if equipped. 7. Install the oil pan drain plug, if equipped. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE CAUTION: ^ Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. ^ Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 1. Install the fuel pressure gauge to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gauge in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gauge. 7. Inspect for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2839 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance Of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 2. Remove the engine sight shield. 3. Loosen the fuel filler cap in order to relieve the fuel tank vapor pressure. 4. Connect the J 34730-1A to the fuel pressure valve. 5. Install the bleed hose of the gauge into an approved container. 6. Open the valve on the gauge to bleed the system pressure. The fuel connections are now safe for servicing. 7. Drain any fuel remaining in the gauge into an approved container. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Mechanical Specifications Oil Filter: Mechanical Specifications Fastener Tightening Specifications Oil Filter ............................................................................................................................................... .................................................... 30 Nm (22 ft. lbs.) Oil Filter Fitting .................................................. ....................................................................................................................................... 55 Nm (40 ft. lbs.) Engine Mechanical Specifications (5.3L Engine) Oil Filter Type ...................................................................................................................................... ......................................................................... PF59 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Mechanical Specifications > Page 2849 Oil Filter: Capacity Specifications Oil Capacity With Filter Change ............................................................................................................................... ......................................... 5.68 Liters (6.0 Quarts) Without Filter Change .......................................... ........................................................................................................................ 4.73 Liters (5.0 Quarts) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Mechanical Specifications > Page 2850 Oil Filter: Fluid Type Specifications Oil Type ............................................................................................................................................... ....................................................................... 5W-30 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 2851 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug hole and plug. 8. Remove the oil filter from the engine block. Important: Check the old oil filter to ensure that the filter seal is not left on the engine block. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 2852 1. Lubricate the oil filter seal with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter to the engine block. - Tighten the oil filter to 30 Nm (22 ft. lbs.). 3. install the oil drain plug to the engine block. - Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator in order to check the level. 10. Add oil if necessary: 11. Close the hood. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Filter: > 03-01-38-019A > Sep > 04 > A/C - Underhood Rattle Noise on Hard Acceleration Refrigerant Filter: Customer Interest A/C - Underhood Rattle Noise on Hard Acceleration File In Section: 01 - HVAC Bulletin No.: 03-01-38~019A Date: September, 2004 TECHNICAL Subject: Underhood Rattle Noise Heard On Acceleration (Check A/C System Performance and Compressor Operation) Models: 2003-2004 Cadillac CTS 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 2002-2004 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2002-2004 GMC Denali, Denali XL, Savana, Sierra, Yukon, Yukon XL 2002-2004 Commercial Upfitter Chassis Vehicles with Air Conditioning (A/C) This bulletin is being revised to update the service procedure and parts information. Please discard Corporate Bulletin Number 03-01-38-019 (Section 01 - HVAC). Condition Some customers may comment about an underhood rattle noise heard on acceleration or a sudden loss of A/C system performance. Cause This condition may be caused by liquid slugging of the A/C compressor. This condition may cause an internal failure in the A/C compressor. The serpentine belt tensioner and serpentine belt may also be damaged. Correction Technicians are to check the A/C system performance and compressor operation using the following repair procedure: 1. Open the hood and inspect the A/C compressor for damage and to see if the compressor is seized. Verify that the serpentine belt is not damaged or missing. If the A/C compressor is seized, proceed to Step 5. 2. Perform the A/C System Performance test. Refer to the Heating, Ventilation and Air Conditioning (HVAC) section of SI. Correct any performance concerns or refrigerant leaks that are found. 3. Inspect the vehicle for other possible sources of A/C compressor noise or performance concerns. Refer to Corporate Bulletin Number 01-01-38-013 for more information. 4. After all other possible sources of A/C compressor noise or performance concerns have been eliminated, only then should the A/C compressor be replaced. 5. Remove the A/C compressor. Refer to the A/C Compressor Replacement procedure in the HVAC section of SI. 6. Inspect the transmission cooler lines for damage due to contact from the serpentine belt. Replace the transmission cooler lines if necessary. 7. Install an inline A/C system filter. Refer to Corporate Bulletin Number 01-01-38-006C for more information about A/C system flushing and filter installation procedures. An A/C system flush is not to be done unless prior authorization is given by the GM Area Service Manager (in Canada, the District Service Manager). 8. Install an A/C Suction Screen. Refer to Corporate Bulletin Number 01-01-39-003A for more information about A/C suction screen repair recommendations and procedures. 9. Install a new A/C compressor. Refer to the Compressor Replacement procedure in the HVAC section of SI. 10. Install a new orifice tube for the front A/C system. Refer to the Expansion (Orifice) Tube Replacement procedure in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Filter: > 03-01-38-019A > Sep > 04 > A/C - Underhood Rattle Noise on Hard Acceleration > Page 2861 11. If the vehicle is a 2003 model year Chevrolet Express or GMC Savana van, the vehicle may require a new accumulator. Refer to Corporate Bulletin Number 03-01-38-016 for more information. This bulletin refers to an updated design accumulator that may improve the performance of the A/C system. 12. Install a new serpentine belt tensioner and serpentine belt if they have been damaged due to A/C system slugging or an A/C compressor seizure. The serpentine belt tensioner may have broken stop tabs and/or a missing front cap. 13. Verify proper operation of the A/C system. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Filter: > 03-01-38-019A > Sep > 04 > A/C - Underhood Rattle Noise on Hard Acceleration Refrigerant Filter: All Technical Service Bulletins A/C - Underhood Rattle Noise on Hard Acceleration File In Section: 01 - HVAC Bulletin No.: 03-01-38~019A Date: September, 2004 TECHNICAL Subject: Underhood Rattle Noise Heard On Acceleration (Check A/C System Performance and Compressor Operation) Models: 2003-2004 Cadillac CTS 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 2002-2004 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2002-2004 GMC Denali, Denali XL, Savana, Sierra, Yukon, Yukon XL 2002-2004 Commercial Upfitter Chassis Vehicles with Air Conditioning (A/C) This bulletin is being revised to update the service procedure and parts information. Please discard Corporate Bulletin Number 03-01-38-019 (Section 01 - HVAC). Condition Some customers may comment about an underhood rattle noise heard on acceleration or a sudden loss of A/C system performance. Cause This condition may be caused by liquid slugging of the A/C compressor. This condition may cause an internal failure in the A/C compressor. The serpentine belt tensioner and serpentine belt may also be damaged. Correction Technicians are to check the A/C system performance and compressor operation using the following repair procedure: 1. Open the hood and inspect the A/C compressor for damage and to see if the compressor is seized. Verify that the serpentine belt is not damaged or missing. If the A/C compressor is seized, proceed to Step 5. 2. Perform the A/C System Performance test. Refer to the Heating, Ventilation and Air Conditioning (HVAC) section of SI. Correct any performance concerns or refrigerant leaks that are found. 3. Inspect the vehicle for other possible sources of A/C compressor noise or performance concerns. Refer to Corporate Bulletin Number 01-01-38-013 for more information. 4. After all other possible sources of A/C compressor noise or performance concerns have been eliminated, only then should the A/C compressor be replaced. 5. Remove the A/C compressor. Refer to the A/C Compressor Replacement procedure in the HVAC section of SI. 6. Inspect the transmission cooler lines for damage due to contact from the serpentine belt. Replace the transmission cooler lines if necessary. 7. Install an inline A/C system filter. Refer to Corporate Bulletin Number 01-01-38-006C for more information about A/C system flushing and filter installation procedures. An A/C system flush is not to be done unless prior authorization is given by the GM Area Service Manager (in Canada, the District Service Manager). 8. Install an A/C Suction Screen. Refer to Corporate Bulletin Number 01-01-39-003A for more information about A/C suction screen repair recommendations and procedures. 9. Install a new A/C compressor. Refer to the Compressor Replacement procedure in the HVAC section of SI. 10. Install a new orifice tube for the front A/C system. Refer to the Expansion (Orifice) Tube Replacement procedure in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Filter: > 03-01-38-019A > Sep > 04 > A/C - Underhood Rattle Noise on Hard Acceleration > Page 2867 11. If the vehicle is a 2003 model year Chevrolet Express or GMC Savana van, the vehicle may require a new accumulator. Refer to Corporate Bulletin Number 03-01-38-016 for more information. This bulletin refers to an updated design accumulator that may improve the performance of the A/C system. 12. Install a new serpentine belt tensioner and serpentine belt if they have been damaged due to A/C system slugging or an A/C compressor seizure. The serpentine belt tensioner may have broken stop tabs and/or a missing front cap. 13. Verify proper operation of the A/C system. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) Refrigerant Filter: Service and Repair A/C Refrigerant Filter Installation (C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C Refrigerant filter, AC P/N 15-1696 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. 2. Measure 50 mm (2 in) from the bend on the evaporator tube (2) near the expansion tube end and mark the location. 3. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs. 4. Using a tubing cutter, cut the marked section of the evaporator tube (2). 5. Remove the burrs from the evaporator tube (2). 6. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. 7. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 8. Install the ferrules (3) with the small end toward the nut (4). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2870 9. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 10. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 11. Remove the nuts (4) from the A/C refrigerant filter (1). 12. Coat the O-rings (2) with 525 viscosity refrigerant oil. 13. Install the O-rings (2) to the evaporator tube halves. 14. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fittings of the component using the J 39400-A. 17. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2871 Refrigerant Filter: Service and Repair A/C Refrigerant Filter Installation (C69) TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C refrigerant filter, AC P/N 15-1696 must be installed to the A/C evaporator tube (liquid line) between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. 2. Remove the evaporator tube (2) from the vehicle. 3. Measure 45 mm (1.75 in) from the bend on the condenser end of the evaporator tube (2) and mark the location. 4. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) towards the evaporator from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs. 5. Using a tubing cutter, cut the marked section of the evaporator tube (2). 6. Remove the burrs from the evaporator tube (2). 7. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: Do Not install the O-rings (2) in this step. 8. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 9. Install the ferrules (3) with the small end toward the nut (4). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2872 10. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 11. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 12. Remove the nuts (4) from the A/C refrigerant filter (1). 13. Coat the O-rings (2) with 525 viscosity refrigerant oil. 14. Install the O-rings (2) to the evaporator tube halves. 15. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2873 16. Install the evaporator tube (2) to the vehicle. 17. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 18. Leak test the fittings of the component using the J 39400-A. 19. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2874 Refrigerant Filter: Service and Repair A/C Refrigerant Filter Replacement (C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. IMPORTANT: The nuts (4) and the ferrules (3) will remain on the evaporator tube. Do not try to remove. 3. Remove the nuts (4) from the A/C refrigerant filter (1). 4. Remove the A/C refrigerant filter (3) from the evaporator tube (2). INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2875 1. Coat the O-rings (2) with 525 viscosity refrigerant oil. 2. Install the O-rings (2) to the evaporator tube. 3. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2876 4. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2877 Refrigerant Filter: Service and Repair A/C Refrigerant Filter Replacement (C69) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. 3. Remove the evaporator tube (2) from the vehicle. IMPORTANT: The nuts (4) and ferrules (3) will remain on the evaporator tube. Do not try to remove. 4. Remove the nuts (4) from the A/C refrigerant filter (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2878 5. Remove the A/C refrigerant filter (3) from the evaporator tube (2). INSTALLATION PROCEDURE 1. Lubricate the O-rings (2) with 525 viscosity refrigerant oil. 2. Install the O-rings (2) to the evaporator tube. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2879 3. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2880 5. Install the evaporator tube (2) to the vehicle. 6. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fitting(s) of the repaired or reinstalled component using the J39400-A. 8. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2881 Refrigerant Filter: Service and Repair A/C Refrigerant Filter Installation (C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C Refrigerant filter, AC P/N 15-1696 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. 2. Measure 50 mm (2 in) from the bend on the evaporator tube (2) near the expansion tube end and mark the location. 3. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs. 4. Using a tubing cutter, cut the marked section of the evaporator tube (2). 5. Remove the burrs from the evaporator tube (2). 6. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. 7. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 8. Install the ferrules (3) with the small end toward the nut (4). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2882 9. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 10. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 11. Remove the nuts (4) from the A/C refrigerant filter (1). 12. Coat the O-rings (2) with 525 viscosity refrigerant oil. 13. Install the O-rings (2) to the evaporator tube halves. 14. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fittings of the component using the J 39400-A. 17. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes A/C Refrigerant Filter Installation (C69) TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2883 J 39400-A Halogen Leak Detector IMPORTANT: The A/C refrigerant filter, AC P/N 15-1696 must be installed to the A/C evaporator tube (liquid line) between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. 2. Remove the evaporator tube (2) from the vehicle. 3. Measure 45 mm (1.75 in) from the bend on the condenser end of the evaporator tube (2) and mark the location. 4. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) towards the evaporator from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs. 5. Using a tubing cutter, cut the marked section of the evaporator tube (2). 6. Remove the burrs from the evaporator tube (2). 7. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: Do Not install the O-rings (2) in this step. 8. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 9. Install the ferrules (3) with the small end toward the nut (4). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2884 10. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 11. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 12. Remove the nuts (4) from the A/C refrigerant filter (1). 13. Coat the O-rings (2) with 525 viscosity refrigerant oil. 14. Install the O-rings (2) to the evaporator tube halves. 15. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2885 16. Install the evaporator tube (2) to the vehicle. 17. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 18. Leak test the fittings of the component using the J 39400-A. 19. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes A/C Refrigerant Filter Replacement (C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. IMPORTANT: The nuts (4) and the ferrules (3) will remain on the evaporator tube. Do not try to remove. 3. Remove the nuts (4) from the A/C refrigerant filter (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2886 4. Remove the A/C refrigerant filter (3) from the evaporator tube (2). INSTALLATION PROCEDURE 1. Coat the O-rings (2) with 525 viscosity refrigerant oil. 2. Install the O-rings (2) to the evaporator tube. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2887 3. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes A/C Refrigerant Filter Replacement (C69) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. 3. Remove the evaporator tube (2) from the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2888 IMPORTANT: The nuts (4) and ferrules (3) will remain on the evaporator tube. Do not try to remove. 4. Remove the nuts (4) from the A/C refrigerant filter (1). 5. Remove the A/C refrigerant filter (3) from the evaporator tube (2). INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2889 1. Lubricate the O-rings (2) with 525 viscosity refrigerant oil. 2. Install the O-rings (2) to the evaporator tube. 3. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2890 4. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 5. Install the evaporator tube (2) to the vehicle. 6. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fitting(s) of the repaired or reinstalled component using the J39400-A. 8. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Suction Screen Installation TOOL REQUIRED J 44551 Suction Screen Kit IMPORTANT: Suction screens are intended to be installed in the suction hose after a major compressor failure. The suction screens are available in 3 different sizes. 1. Insert the J 44551-6 sizing tool into the suction hose to select the correct size suction screen. 2. Insert the suction screen into the compressor end of the suction hose. 3. Install the correct mandrel to the J 44551-5. 4. Install the J 44551-5 screen installation tool over the end of the suction hose and the suction screen. IMPORTANT: Correct placement of the J 44551-5 is critical. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 2891 5. Tighten the forcing screw of the J 44551-5. The suction screen is fully installed when the screen is flush with the end of the suction hose fitting. 6. Remove the J 44551-5 suction screen tool from the suction hose. IMPORTANT: After a major compressor failure an A/C refrigerant filter should also be installed. 7. Install an A/C refrigerant filter. 8. Install the J 44551-1 Suction Screen Notification label. Suction Screen Replacement TOOLS REQUIRED - J 42220 Universal Leak Detection Lamp - J 44551 Suction Screen Kit REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the A/C compressor hose assembly bolt. 3. Separate the A/C compressor hose assembly from the A/C compressor. IMPORTANT: The suction screens are available in 3 different sizes. 4. Select the proper size removal tool from the J 44551. 5. Remove the suction screen using the J 44551-31 suction screen removal tool. - Thread the forcing screw into the suction screen. - Tighten the nut on the forcing screw to remove the suction screen. INSTALLATION PROCEDURE 1. Insert the J 44551-6 sizing tool into the suction hose to select the correct size suction screen. 2. Insert the suction screen into the suction hose. 3. Install the J 44551-3 mandrel to the J 44551-5. 4. Install the J 44551-5 suction screen installation tool over the end of the suction hose and the suction screen. IMPORTANT: Correct placement of the J 44551-5 is critical. 5. Tighten the forcing screw of the J 44551-5. The suction screen is fully installed when the screen is flush with the end of the suction hose. 6. Remove the J 44551-5 suction screen tool from the suction hose. 7. Replace the seal washers. Refer to Compressor Sealing Washers Replacement. 8. Install the A/C compressor hose assembly to the A/C compressor. NOTE: Refer to Fastener Notice in Service Precautions. 9. Install the A/C compressor hose assembly bolt. Tighten Tighten the bolt to 34 N.m (25 lb ft). 10. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 11. Leak test the fittings of the component using the J 42220. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement Coolant Line/Hose: Service and Repair Radiator Vent Inlet Hose Replacement Radiator Vent Inlet Hose Replacement Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Reposition the vent inlet hose clamp from the radiator. 3. Remove the vent inlet hose from the radiator. 4. Reposition the vent inlet hose clamp from the surge tank. 5. Remove the vent inlet hose from the surge tank. Installation Procedure 1. Install the vent inlet hose to the surge tank. 2. Reposition the vent inlet hose clamp to the surge tank. 3. Install the vent inlet hose to the radiator. 4. Reposition the vent inlet hose clamp to the radiator. 5. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 2897 Coolant Line/Hose: Service and Repair Surge Tank Hose/Pipe Replacement - Inlet Surge Tank Hose/Pipe Replacement - Inlet Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Reposition the surge tank inlet hose clamp from the radiator. 3. Remove the surge tank inlet hose from the radiator. 4. Reposition the surge tank inlet hose clamp at the surge tank. 5. Remove the surge tank inlet hose (1) from the surge tank. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 2898 1. Install the surge tank inlet hose (1) to the surge tank. 2. Position the surge tank inlet hose clamp to the surge tank. 3. Install the surge tank inlet hose to the radiator. 4. Position the surge tank inlet hose clamp to the radiator. 5. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 2899 Coolant Line/Hose: Service and Repair Surge Tank Hose/Pipe Replacement - Outlet Surge Tank Hose/Pipe Replacement - Outlet (4.8L, 5.31-, and 6.0L Engines) - Tools Required J 43181 Heater Line Quick Connect Release Tool Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Loosen the air cleaner outlet duct clamps at the following locations: - Throttle body - Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the air cleaner outlet duct. 4. If equipped without regular production option (RPO) C36 auxiliary heater, remove the surge tank/heater outlet hose (1) from the mounting clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 2900 5. If equipped with RPO C36 auxiliary heater, remove the surge tank theater outlet hose (1) from the mounting clip. 6. Install the J 43181 to the surge tank outlet hose. 7. Close the J 43181 around the surge tank outlet hose. 8. Firmly pull the J 43181 into the quick connect end of the outlet hose. 9. If equipped without RPO C36 auxiliary heater, firmly grasp the outlet hose. Pull the outlet hose in order to disengage the hose from the heater and blower module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 2901 10. If equipped with RPO C36 auxiliary heater, firmly grasp the outlet hose. Pull the outlet hose in order to disengage the hose from the heater and blower module. 11. Reposition the surge tank outlet hose clamp at the surge tank. 12. Remove the surge tank outlet hose (2) from the surge tank. 13. Reposition the surge tank outlet hose clamp at the water pump. 14. Remove the surge tank outlet hose from the water pump. 15. Remove the surge tank outlet hose. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 2902 1. Install the surge tank outlet hose. 2. Install the surge tank outlet hose to the water pump. 3. Position the surge tank outlet hose clamp to the water pump. 4. Install the surge tank outlet hose (2) to the surge tank. 5. Position the surge tank outlet hose clamp to the surge tank. 6. If equipped with RPO C36 auxiliary heater, connect the surge tank outlet hose to the heater and blower module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 2903 7. If equipped without RPO C36 auxiliary heater, connect the surge tank outlet hose to the heater and blower module. Firmly push the hose onto the heater and blower module pipe until an audible click is heard. 8. If equipped with RPO C36 auxiliary heater, install the surge tank/heater outlet hose (1) to the mounting clip. 9. If equipped without RPO C36 auxiliary heater, install the surge tank/heater outlet hose (1) to the mounting clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 2904 10. Install the air cleaner outlet duct. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. 11. Tighten the air cleaner outlet duct clamps at the following locations: - Throttle body - MAF/IAT sensor - Tighten the air cleaner outlet duct clamp screws to 7 Nm (62 inch lbs.). 12. Fill the cooling system, Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Heater Hose: Service and Repair Heater Pipe Replacement - Auxiliary REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the auxiliary heater pipes (1, 2) from the heater inlet and outlet tees (3, 4). 3. Loosen the right front wheelhouse to gain access to the clamp behind the wheelhouse. Refer to Wheelhouse Panel Replacement in Body Front End. 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Remove the auxiliary heater pipes (2, 3) from the auxiliary heater core. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 2909 6. Remove the heater/A/C tubes retaining nut (4) from the stud (1) at the frame (6). 7. Remove the auxiliary heater pipes (2) from the clamps (5). 8. Remove the auxiliary heater pipes from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary healer pipes to the vehicle. 2. Install the auxiliary heater pipes (2) to the clamps (5). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the heater/A/C tubes retaining nut (4)10 the stud (1) at the frame (6). Tighten Tighten the heater/A/C tubes retaining nut to 7 N.m (62 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 2910 4. Install the auxiliary heater pipes (2, 3) to the auxiliary heater core. 5. Lower the vehicle. Refer to Lifting and Jacking the Vehicle. 6. Install the right front wheelhouse. 7. Install the auxiliary heater pipes (1, 2)10 the heater inlet and outlet tees (3, 4). 8. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 2911 Heater Hose: Service and Repair Heater Hose Replacement - Inlet REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. 5. Pull the connection apart. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 2912 6. Remove the inlet heater hose from the water pump. 7. Remove the inlet heater hose. INSTALLATION PROCEDURE 1. Install the inlet heater hose. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 2913 2. Install the inlet heater hose to the water pump. 3. Connect the heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hoses to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 2914 Heater Hose: Service and Repair Heater Hose Replacement - Outlet REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. 5. Pull the connection apart. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 2915 6. Remove the outlet heater hose from the water pump. 7. Reposition the outlet heater hose clamp at the surge tank. 8. Remove the outlet heater hose from the surge tank. 9. Remove the outlet heater hose. INSTALLATION PROCEDURE 1. Install the outlet heater hose. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 2916 2. Install the outlet heater hose to the water pump. 3. Install the outlet heater hose to the surge tank. 4. Install the outlet heater hose clamp to the surge tank. 5. Connect the heater and surge tank hoses to the heater core. Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Install the heater and surge tank hoses to the mounting clip. 7. Install the air intake tube. 8. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 2917 Heater Hose: Service and Repair Heater and A/C Pipe Repair - Auxiliary TOOLS REQUIRED J 41425 A/C Line Repair Kit Do not service the rear A/C or heater lines as a complete unit. Service the rear A/C or heater lines as a sectional repair. You can obtain the various sections of line through GMSPO. Use the J 41425 when any of the following actions damage the rear A/C or heater lines: - Rub-through - Collision damage - Leakage in the system Minimum Tube Length Required Table IMPORTANT: When you section the rear A/C or heater lines, ensure that the correct minimum length remains in the straight part of the line on both sides of the splice. Follow the Straight Line Repair procedure in order to repair line damage in a straight section of line. Follow the Line Sectioning Repair procedure in order to repair any damage in a bend area. Do not repair the rear A/C or heater lines in a bend area, replace the lines. Maintaining the original line shape will prevent vibrations and rub-through. Straight Line Repair 1. Recover the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. 2. Drain the coolant, if repairing the heater lines. Refer to Draining and Filling Cooling System in Engine Cooling. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Locate the area that requires repair. 5. Obtain a length of replacement line to make the repair. 6. Use a tubing cutter in order to cut and remove the section of damaged line. IMPORTANT: The length of the replacement line must be the same as the section being replaced. 7. Use a tubing cutter in order to cut the replacement line to length. 8. Use the cleaning pad from the J41425 in order to clean any burrs or grease from the line ends. Be sure to clean at least 19 mm (0.75 in) from the line ends. 9. Use the LOK prep sealant in order to prep the line ends. 10. Apply one drop of the J 41425-3 sealing compound to the outside of each end of the line. 11. Insert the line ends into the LOK fitting. 12. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines. 13. Install the correct LOK fitting jaws into the J 41425-1 tool. 14. Install the J 41425-1 tool over the LOK connectors. Verify that the LOK connector ends are positioned in the counter bores of the jaws. IMPORTANT: Hold the J 41425-1 tool body with a 3/8" breaker bar. 15. Tighten the forcing screw of the J 41425-1 tool. When fully seated, the LOK connector collars will bottom out on the center shoulder of the LOK fitting. 16. Loosen the forcing screw and remove the J 41425-1 tool from the repaired line. 17. Repeat Step 8 through Step 16 to repair the other end of the line. 18. Verify that the LOK fittings are correctly installed. 19. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 2918 20. Refill the coolant, if drained. Refer to Draining and Filling Cooling System in Engine Cooling. 21. Evacuate and recharge the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. Line Sectioning Repair 1. Recover the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. 2. Drain the coolant, if repairing the heater lines. Refer to Draining and Filling Cooling System in Engine Cooling. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Obtain a new A/C or heater line for sectioning. IMPORTANT: Stagger the splices if repairing more than one line. 5. Scribe a mark on the line that will be sectioned. 6. Use a tubing cutter in order to cut the line or lines being replaced. 7. Remove the section of line being replaced from the vehicle. IMPORTANT: The length of the replacement line must be the same as the line being replaced. 8. Install the replacement line to the vehicle. 9. Use a tubing cutter in order to cut the replacement line to length. 10. Use the cleaning pad from the J 41425 in order to clean any burrs or grease. Be sure to clean at least 19 mm (0.75 in) from the A/C line. 11. Use the LOK prep sealant in order to prep the A/C or heater line. 12. Apply one drop of the J 41425-3 sealing compound to the outside of each line end. 13. Insert the line ends into the LOK fitting. 14. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines. 15. Install the correct LOK fitting jaws into the J41425-1 tool. 16. Install the J 41425-1 tool over the LOK connectors. Verify that the LOK connector ends are positioned in the counter bores of the jaws. 17. Hold the tool body with a 3/8" breaker bar. Turn the forcing screw until both of the connector collars bottom on the center shoulder of the LOK fitting. 18. Loosen the forcing screw. Remove the tool from the repaired line. 19. Verify that the LOK fitting is correctly installed. 20. Lower the vehicle. 21. Refill the coolant, if drained. Refer to Draining and Filling Cooling System in Engine Cooling. 22. Evacuate and recharge the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 Hose/Line HVAC: Customer Interest Suspension - Service Ride Control Message/DTC C0580 Bulletin No.: 03-03-11-001 Date: July 22, 2003 TECHNICAL Subject: Service Ride Control Message Displayed, DTC C0580 Set (Replace Right Front Shock Absorber Solenoid Connector and Install New A/C Suction Hose and Auxiliary A/C Evaporator Hose) Models: 2002-2003 Cadillac Escalade 2003 Cadillac Escalade ESV 2001-2003 Chevrolet Suburban, Tahoe 2001-2003 GMC Yukon, Yukon XL with Rear Air Conditioning System (RPO C69) and Real Time Damping Chassis Package (RPO Z55) Condition Some customers may comment on the Service Ride Control message being displayed. Upon investigation, the technician may find DTC C0580 set. Cause Poor clearance between the auxiliary A/C evaporator hose and the right front shock absorber damper solenoid connector may be the cause of this condition. Contact may occur damaging the connector and causing a poor connection at the damper solenoid. Correction Replace the right front shock absorber solenoid connector and install a new A/C suction hose and auxiliary A/C evaporator hose. These new A/C hoses will provide proper routing to prevent contact between the auxiliary A/C evaporator hose and the right front shock absorber damper solenoid connector. Use the procedure listed below. 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 3. Remove the right front wheel assembly. 4. Remove the right front wheelhouse panel. 5. Remove the nut and the auxiliary evaporator hose from the accumulator line block. 6. Remove the nut and the suction hose from the accumulator. 7. Remove the bolt and the suction hose from the compressor. 8. Install the new suction hose and bolt to the compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). 9. Install the new suction hose and nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 10. Release 4 line retaining clamps, starting at the wheelhouse and along the underbody towards the rear of vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 > Page 2927 11. From under the vehicle, mark the location on the auxiliary evaporator line where the line will be cut. Using the forward running board bracket as a reference, mark the location inline with the bracket-to-body bolt (1). If the vehicle is not equipped with running boards, mark the location inline with the bolt hole. 12. Using a tubing cutter, cut the marked section of the auxiliary evaporator line. 13. Remove the front section of the auxiliary evaporator hose from the vehicle and discard. 14. Install the new front section of the auxiliary evaporator hose into the vehicle. 15. On both sections of the auxiliary evaporator line, cut back the plastic coating approximately 76 mm (3 in). 16. Splice in the new front section of the auxiliary evaporator hose using J 41425 A/C Line Repair Kit and J 41425-750 splice. Refer to the Heater and A/C Pipe Repair-Auxiliary procedure in the Service Manual. 17. Install the auxiliary evaporator hose to the accumulator line block and nut. Tighten Tighten the nut to 16 N.m (12 lb ft). 18. Secure the line retaining clamps. 19. Install the wheelhouse panel. 20. Install the wheel assembly. 21. Lower the vehicle. 22. Inject the oil into the A/C system that was removed during the recovery process using J 45037 A/C Oil Injection Kit. 23. Evacuate and recharge the refrigerant. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. 24. Leak test the fitting and splice using J 39400-A Halogen Leak Detector. 25. Replace the right front shock absorber solenoid connector using service connector, P/N 88986417. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 > Page 2928 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 Hose/Line HVAC: All Technical Service Bulletins Suspension - Service Ride Control Message/DTC C0580 Bulletin No.: 03-03-11-001 Date: July 22, 2003 TECHNICAL Subject: Service Ride Control Message Displayed, DTC C0580 Set (Replace Right Front Shock Absorber Solenoid Connector and Install New A/C Suction Hose and Auxiliary A/C Evaporator Hose) Models: 2002-2003 Cadillac Escalade 2003 Cadillac Escalade ESV 2001-2003 Chevrolet Suburban, Tahoe 2001-2003 GMC Yukon, Yukon XL with Rear Air Conditioning System (RPO C69) and Real Time Damping Chassis Package (RPO Z55) Condition Some customers may comment on the Service Ride Control message being displayed. Upon investigation, the technician may find DTC C0580 set. Cause Poor clearance between the auxiliary A/C evaporator hose and the right front shock absorber damper solenoid connector may be the cause of this condition. Contact may occur damaging the connector and causing a poor connection at the damper solenoid. Correction Replace the right front shock absorber solenoid connector and install a new A/C suction hose and auxiliary A/C evaporator hose. These new A/C hoses will provide proper routing to prevent contact between the auxiliary A/C evaporator hose and the right front shock absorber damper solenoid connector. Use the procedure listed below. 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 3. Remove the right front wheel assembly. 4. Remove the right front wheelhouse panel. 5. Remove the nut and the auxiliary evaporator hose from the accumulator line block. 6. Remove the nut and the suction hose from the accumulator. 7. Remove the bolt and the suction hose from the compressor. 8. Install the new suction hose and bolt to the compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). 9. Install the new suction hose and nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 10. Release 4 line retaining clamps, starting at the wheelhouse and along the underbody towards the rear of vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 > Page 2934 11. From under the vehicle, mark the location on the auxiliary evaporator line where the line will be cut. Using the forward running board bracket as a reference, mark the location inline with the bracket-to-body bolt (1). If the vehicle is not equipped with running boards, mark the location inline with the bolt hole. 12. Using a tubing cutter, cut the marked section of the auxiliary evaporator line. 13. Remove the front section of the auxiliary evaporator hose from the vehicle and discard. 14. Install the new front section of the auxiliary evaporator hose into the vehicle. 15. On both sections of the auxiliary evaporator line, cut back the plastic coating approximately 76 mm (3 in). 16. Splice in the new front section of the auxiliary evaporator hose using J 41425 A/C Line Repair Kit and J 41425-750 splice. Refer to the Heater and A/C Pipe Repair-Auxiliary procedure in the Service Manual. 17. Install the auxiliary evaporator hose to the accumulator line block and nut. Tighten Tighten the nut to 16 N.m (12 lb ft). 18. Secure the line retaining clamps. 19. Install the wheelhouse panel. 20. Install the wheel assembly. 21. Lower the vehicle. 22. Inject the oil into the A/C system that was removed during the recovery process using J 45037 A/C Oil Injection Kit. 23. Evacuate and recharge the refrigerant. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. 24. Leak test the fitting and splice using J 39400-A Halogen Leak Detector. 25. Replace the right front shock absorber solenoid connector using service connector, P/N 88986417. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 > Page 2935 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 2936 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement Hose/Line HVAC: Service and Repair Evaporator Tube Replacement TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube nut from the evaporator. 3. Disconnect the evaporator tube from the evaporator. 4. Remove the evaporator tube nut from the auxiliary A/C tube (if equipped). 5. Disconnect the evaporator tube from the auxiliary A/C tube (if equipped). 6. Remove the right park/turn signal lamp. 7. Remove the grille from the vehicle. 8. Remove the evaporator tube nut from the condenser. 9. Disconnect the evaporator tube from the condenser. 10. Remove the evaporator tube from the vehicle. 11. Discard all of the used sealing washers. Cap all of the open connections. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 2939 1. Connect the evaporator tube to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the evaporator tube nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 3. Install the grille to the vehicle. 4. Install the right park/turn signal lamp. 5. Connect the evaporator tube to the auxiliary A/C tube using new sealing washers (if equipped). 6. Install the evaporator tube nut to the auxiliary A/C tube (if equipped). Tighten Tighten the nut to 16 N.m (12 lb ft). 7. Connect the evaporator tube to the evaporator. 8. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 9. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 10. Leak test the fittings of the components using the J 39400-A. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 2940 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the suction hose mounting bolt from the A/C compressor. 3. Remove the suction hose (2) from the A/C compressor. 4. Remove the suction hose nut from the accumulator. 5. Remove the suction hose from the accumulator. 6. Remove the suction hose assembly from the vehicle. 7. Discard all of the used sealing washers. Cap the system openings. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 2941 1. Install the suction hose to the vehicle. 2. Install the suction hose to the accumulator. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 4. Install the suction hose (2) to the compressor using new sealing washers. 5. Install the suction hose mounting bolt to the A/C compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). 6. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fittings of the component using the J 39400-A. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 2942 Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the discharge hose mounting bolt (2) from the A/C compressor. 3. Remove the discharge hose (1) from the A/C compressor. 4. Remove the upper radiator baffle. 5. Remove the discharge hose nut from the condenser. 6. Remove the discharge hose from the condenser. 7. Disconnect the electrical connector from the A/C recirculation switch. 8. Remove the discharge hose from the vehicle. 9. Discard all of the used sealing washers. Cap the system openings. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 2943 1. Install the discharge hose (1) to the vehicle. 2. Connect the electrical connector to the A/C recirculation switch. 3. Install the discharge hose to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the discharge hose nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 5. Install the upper air baffle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 2944 6. Install the discharge hose (1) to the A/C compressor using new sealing washers. 7. Install the discharge hose mounting bolt. Tighten Tighten the bolt to 16 N.m (12 lb ft). 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 2945 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement - Auxiliary TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the auxiliary A/C evaporator tubes (3) from the condenser tube (2) and the accumulator (5). 3. Loosen the right front wheelhouse to gain access to the clamp behind the wheelhouse. Refer to Wheelhouse Panel Replacement in Body Front End. 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Remove the retaining nut (2) and the auxiliary A/C evaporator tubes (3) from the auxiliary HVAC module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 2946 6. Remove the heater/A/C tubes retaining nut (4) from the stud (1) at the frame (6). 7. Remove the auxiliary A/C evaporator tubes (3) from the clamps (5). 8. Remove the auxiliary A/C evaporator tubes from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary A/C evaporator tubes to the vehicle. 2. Install the auxiliary A/C evaporator tubes (3) to the clamps (5). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the heater/A/C tubes retaining nut (4) to the stud (1) at the frame (6). Tighten Tighten the heater/A/C tubes retaining nut to 7 N.m (62 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 2947 4. Install the auxiliary A/C evaporator tubes (2, 3) and the retaining nut to the auxiliary HVAC module. Tighten Tighten the nut to 16 N.m (12 lb ft). 5. Lower the vehicle. Refer to Lifting and Jacking the Vehicle. 6. Install the right front wheelhouse. Refer to Wheelhouse Panel Replacement in Body Front End. 7. Install the auxiliary A/C evaporator tubes (3) to the condenser tube (2) and the accumulator (5). Tighten Tighten the nuts to 16 N.m (12 lb ft). 8. Recharge the refrigerant to the system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure Hose Connection (At Gear) ........................................................................................................................................................ 33 Nm (24 ft. lbs.) Pressure Hose Connection (At Pump) ...................................................................................................................................................... 28 Nm (20 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Brake Booster Inlet Hose Replacement Power Steering Line/Hose: Service and Repair Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Install a drain pan under the vehicle. 2. Remove the brake booster inlet hose (1) from the brake booster (2). 3. Remove the brake booster inlet hose from the power steering pump. 4. Remove the brake booster inlet hose from the vehicle. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 1. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster inlet hose (1) to the brake booster (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the brake booster inlet hose to the power steering pump. Tighten the brake booster inlet hose fittings to 27 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Brake Booster Inlet Hose Replacement > Page 2953 Power Steering Line/Hose: Service and Repair Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Install a drain pan under the vehicle. 2. Remove the brake booster outlet hose (1) from the brake booster (2). 3. Remove the clamp retaining the brake booster outlet hose to the power steering pump. 4. Remove the brake booster outlet hose from the vehicle. Installation Procedure Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. 1. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster outlet hose (1) to the brake booster (2). Position the clamp at the end of the hose. 3. Install the brake booster outlet hose to the power steering pump (4). Position the clamp at the end of the hose. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Brake Booster Inlet Hose Replacement > Page 2954 Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Hose Replacement With Hydroboost Power Steering Gear Inlet Hose Replacement (With Hydroboost) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Install a drain pan under the vehicle. 2. Remove the power steering gear inlet hose (1) from the brake booster. 3. Remove the power steering gear inlet hose from the power steering gear. 4. Remove the power steering gear inlet hose from the vehicle. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 1. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (1) to the brake booster (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering gear inlet hose to the power steering gear. Tighten the power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Brake Booster Inlet Hose Replacement > Page 2955 Without Hydroboost Power Steering Gear Inlet Hose Replacement (Without Hydroboost) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Install a drain pan under the vehicle. 4. Remove the power steering gear inlet hose (3) from the power steering pump (1). 5. Remove the power steering gear inlet hose from the power steering gear. 6. Remove the power steering gear inlet hose from the vehicle. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 1. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (3) to the power steering pump (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering gear inlet hose to the power steering gear. Tighten the power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Install the engine protection shield. 6. Lower the vehicle. 7. Bleed the power steering system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Brake Booster Inlet Hose Replacement > Page 2956 Power Steering Line/Hose: Service and Repair Power Steering Gear Outlet Hose Replacement Power Steering Gear Outlet Hose Replacement (Recirculating Ball) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Install a drain pan under the vehicle. 2. Remove the power steering gear outlet hose (3) from the steering gear (2). 3. Remove the clamp retaining the power steering gear outlet hose (3) to the power steering pump (1) Remove the power steering gear outlet hose from the power steering pump. 4. Remove the power steering gear outlet hose from the vehicle. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 1. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear outlet hose (3) to the power steering pump (1). Position the clamp at the end of the hose. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering gear outlet hose to the power steering gear. Tighten the outlet hose fitting to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet Radiator Hose: Service and Repair Radiator Hose Replacement - Inlet Radiator Hose Replacement - Inlet Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Loosen the air cleaner outlet duct clamps at the following locations: - Throttle body - Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the air cleaner outlet duct. 4. If necessary, remove the engine sight shield. Refer to Engine Sight Shield Replacement (4.8L, 5.3L, and 6.OL (LQ4) or Engine Sight Shield Replacement (6.OL (L09) in Engine Mechanical - 4.8L, 5.3L, and 6.OL. 5. Remove the radiator vent inlet hose from the radiator inlet hose clips. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 2961 6. Reposition the inlet hose clamp from the radiator. 7. Remove the inlet hose from the radiator. 8. Remove the inlet hose clip from the fan shroud. 9. Reposition the inlet hose clamp from the water outlet. 10. Remove the inlet hose from the water outlet. Installation Procedure 1. Install the inlet hose to the water outlet. 2. Reposition the inlet hose clamp to the water outlet. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 2962 3. Install the inlet hose clip to the fan shroud. 4. Install the inlet hose to the radiator. 5. Reposition the inlet hose clamp to the radiator. 6. Install the radiator vent inlet hose to the radiator inlet hose clips. 7. If necessary, install the engine sight shield, Refer to Engine Sight Shield Replacement (4.8L, 5.3L, and 6.OL (LQ4) or Engine Sight Shield Replacement (6.OL (LQ9) in Engine Mechanical - 4.8L, 5.31L, and 6.OL. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. 8. Install the air cleaner outlet duct. 9. Tighten the air cleaner outlet duct clamps at the following locations: - Throttle body - MAF/IAT sensor - Tighten the air cleaner outlet duct clamp screws to 7 Nm (62 inch lbs.). 10. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 2963 Radiator Hose: Service and Repair Radiator Hose Replacement - Outlet Radiator Hose Replacement - Outlet (4.8L, 5.3L, and 6.OL Engines) Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Loosen the air cleaner outlet duct clamps at the following locations: - Throttle body - Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the air cleaner outlet duct. 4. Reposition the outlet hose clamp from the water pump. 5. Remove the outlet hose from the water pump. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 2964 6. Reposition the outlet hose clamp from the radiator. 7. Remove the outlet hose from the radiator. Installation Procedure 1. Install the outlet hose to the radiator. 2. Reposition the outlet hose clamp to the radiator. 3. Install the outlet hose to the water pump. 4. Reposition the outlet hose clamp to the water pump. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. 5. Install the air cleaner outlet duct. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 2965 6. Install the radiator inlet hose clip to the outlet duct. 7. Tighten the air cleaner outlet duct clamps at the following locations: - Throttle body - MAF/IAT sensor - Tighten the air cleaner outlet duct clamp screws to 7 Nm (62 inch lbs.). 8. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic Brake System Delco Supreme 11 Brake Fluid GM Part No. 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2974 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2975 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2976 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2977 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Add one liter if equipped with rear heating for all engines. Cooling System Capacity VORTEC 4800 V8 Automatic with Front A/C 14.4 qt (US) VORTEC 4800 V8 Automatic with Front and Rear A/C 15.8 qt (US) VORTEC 5300 V8 Automatic with Front A/C 14.4 qt (US) VORTEC 5300 V8 Automatic with Front and Rear A/C 15.8 qt (US) Vehicles equipped with optional air conditioner. VORTEC 6000 V8 Automatic 15.8 qt (US) VORTEC 6000 V8 Automatic with engine oil cooler 15.4 qt (US) Vehicles equipped with optional engine cooler VORTEC 8100 V8 Automatic 20.7 qt (US) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 2980 Coolant: Fluid Type Specifications Engine Coolant 50/50 mixture of clean, drinkable water and use only GM Goodwrench DEX-COOL or Havoline DEX-COOL Coolant. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 2985 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 2986 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 2987 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 2988 Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 4L60-E Pan Removal ........................................................................................... .......................................................................................................... 4.7L (5.0 Qt) Overhaul .............. .............................................................................................................................................................. ............................ 10.6L (11.0 Qt) 4L80-E Dry .................................................................................... ............................................................................................................................ 12.8L (13.5 Qt) Pan Removal .............................................................................................................................................. ....................................................... 7.8L (7.7 Qt) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2991 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E Fluid - A/T: Service and Repair 4L60-E Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining field. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E > Page 2994 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E > Page 2995 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan bolts. ^ Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E > Page 2996 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E > Page 2997 Fluid - A/T: Service and Repair 4L80-E Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Remove the oil pan bolts. 5. Remove the oil pan. 6. Remove the gasket. 7. Remove the magnet. 8. Remove the oil filter. 9. Remove the filter neck seal. 10. The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. 11. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4L60-E > Page 2998 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan to the transmission with seventeen bolts. ^ Tighten the oil pan bolts to 11 Nm (97 inch lbs.). 6. Apply a small amount of sealant GM P/N 12346004 to the treads of the drain plug, if equipped. 7. Install the oil pan drain plug, if equipped. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update Fluid - Differential: Technical Service Bulletins Drivetrain - Front Drive Axle Lubrication Update Bulletin No.: 05-00-90-010 Date: December 07, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Drive Axle Carrier Lubricant Information Models: 1999-2005 Light Duty Trucks 2003-2005 HUMMER H2 2005 Saab 9-7X with Four-Wheel or All-Wheel Drive and Separate Front Drive Axle Carriers This bulletin is being issued to revise the front drive axle carrier lubricant specification in the Maintenance and Lubrication and the Front Drive Axle sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. This information also updates the information found in the Owner Manual. Important: Front drive axle carriers do not require periodic lubricant replacement. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update > Page 3003 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Front Drive Axle (8.25") ....................................................................................................................... ..................................................... 1.66 L (1.75 qts.) Front Drive Axle (9.25") ..................................... ....................................................................................................................................... 1.73 L (1.83 qts.) Rear Drive Axle (8.6") .................................................................................................................. ............................................................. 2.28 L (2.41 qts.) Rear Drive Axle (9.5") ............................... .................................................................................................................................................. 2.6 L (2.75 qts.) Rear Drive Axle (10.5") ...................................................................................................... ......................................................................... 2.6 L (2.75 qts.) Rear Drive Axle (11.5") ................... .......................................................................................................................................................... 3.62 L (3.83 qts.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 3006 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Differential Fluid Type Front (S4WD) Grade ........................................................................................................................... .................................................................................................. GL-5 Viscosity .................................. .............................................................................................................................................................. ................... 80W-90 Front (F4WD) Grade .......................................................................................... ............................................................................................................................. Synthetic Viscosity . .............................................................................................................................................................. .................................................... 75W-90 Rear Grade ....................................................................... ................................................................................................................................................ Synthetic Viscosity ............................................................................................................................... .................................................................................... 75W-90 Front Differential Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Grade ............................. .............................................................................................................................................................. ............................ Synthetic Viscosity .................................................................................................. ................................................................................................................. 75W-90 Front Drive Axle Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Grade ............................. .............................................................................................................................................................. ............................ Synthetic Viscosity .................................................................................................. ................................................................................................................. 75W-90 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case NVG 149 ...................................................................................................................... ..................................................................................... 2.3L (2.4 Qt) NVG 236-246 ........................... .............................................................................................................................................................. ........... 1.9L (2.0 Qt) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 3011 Fluid - Transfer Case: Fluid Type Specifications Transfer Case NVG 149 .............................................................................................................................................. ..................... Auto-Trak II Fluid GM P/N 12378508 NVG 236/246 .......................................................................................................................................................... Auto-Trak II Fluid GM P/N 12378508 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) Fluid - Transfer Case: Service and Repair NVG 149-NP (One Speed Automatic) Transfer Case Fluid Replacement Removal Procedure Important: When performing the following service procedures, use only hand tools to remove and install the fill or drain plugs. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shields from the cross member (if equipped). 3. Remove the fill plug from the transfer case. Important: When draining the transfer case, make sure that an approved drain pan is used. 4. Remove the drain plug from the transfer case. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 3014 Important: If the drain or fill plug have to be replaced, used only aluminum replacement drain plugs. 1. Install the drain plug in the transfer case. ^ Tighten the drain plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill hole with the proper fluid. 3. Install the fill plug. ^ Tighten the drain plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield to the cross member. 5. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 3015 Fluid - Transfer Case: Service and Repair NVG 236/246-NP8 (Two Speed Automatic) Transfer Case Fluid Replacement Removal Procedure Important: When performing the following service procedures, use only hand tools in order to remove and install the fill or drain plugs. Always start the plugs by hand in order to prevent cross threading. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shields. 3. Remove the transfer case fill plug. 4. Remove the transfer case drain plug. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: If the drain or fill plug have to be replaced, used only aluminum replacement drain plugs. Steel plugs will react with the magnesium of Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 3016 the transfer case. 1. Install the transfer case drain plug. ^ Tighten the transfer case drain plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill hole with the approved fluid. 3. Install the transfer case fill plug. ^ Tighten the transfer case fill plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield. 5. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3021 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3022 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 5.7L (6.0 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 3025 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Grade ............................................................... ......................................................................................................................................... 5W-30 (preferred) Above -18° C (0° F) ........................................................................................................... ........................................................ 10W-30, 5W-30 (preferred) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 3026 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug hole and plug. 8. Remove the oil filter from the engine block. Important: Check the old oil filter to ensure that the filter seal is not left on the engine block. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 3027 1. Lubricate the oil filter seal with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter to the engine block. - Tighten the oil filter to 30 Nm (22 ft. lbs.). 3. install the oil drain plug to the engine block. - Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator in order to check the level. 10. Add oil if necessary: 11. Close the hood. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications Power Steering System GM Power Steering Fluid (GM Part No. 1052884 - 1 pint, 1050017 - 1 quart, or equivalent). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 3035 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 3036 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Charge Refrigerant Charge .............................................................................................................................. ............................................................ 0.8 kg (1.8 lb) Refrigerant Charge Utility with Front and Rear A/C ....................................................................................................................................... 1.2 kg (2.7 lb) Refrigerant Charge Suburban with Front and Rear A/C .................................................................................................................................. 1.4 kg (3.0 lb) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 3039 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ..................................................................... R-134a Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 3040 Refrigerant: Service and Repair If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Flushing TOOLS REQUIRED J 43600 Air Conditioning Service Center - J 45268 Flush Adapter Kit - J 41447 Leak Detection Dye - J 41459 Leak Detection Dye Injector - J 42220 Universal Leak Detection Lamp IMPORTANT: Flushing is not intended to remove metal from the A/C system. Flushing is intended to remove the following: Contaminated PAG oil - Desiccant, following a desiccant bag failure - Overcharge of PAG oil - Refrigerant contamination IMPORTANT: Warmer engine or ambient temperature decreases the refrigerant recovery time during the A/C flush procedure. 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the orifice tube. 3. Connect the A/C lines with the orifice tube removed. 4. Remove the A/C compressor. 5. Inspect the end of the suction hose for a suction screen. 6. Remove the suction screen, if installed. 7. Install the J 45268-4 to the A/C compressor suction hose. 8. install the J 45268-5 to the A/C compressor discharge hose. 9. Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil. Perform the following procedure: IMPORTANT: The filter inside the J 45268-1 is serviceable. Remove and discard the check valve from the filter. 9.1. Service the filter with AC P/N GF 470, before each flush. Connect the J 45268-1 flush filter to the suction port of the J 45268-4 flush adapter. 9.2. Connect the blue hose from the J 43600 to the J 45268-1 flush filter adapter. 9.3. Connect the red hose from the J 43600 to the J 45268-5 flush adapter. 10. Reverse flow refrigerant flushing is recommended for desiccant bag failure. Perform the following procedure and replace the accumulator when the flush procedure is complete. IMPORTANT: The filter inside the J 45268-1 is serviceable. Remove and discard the check valve from the filter. 10.1. Service the filter with AC P/N GF 470, before each flush. Connect the J 45268-1 flush filter to the discharge port of the J 45268-5 flush adapter. 10.2. Connect the blue hose from the J 43600 to the J 45268-1 flush filter adapter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 3041 10.3. Connect the red hose from the J 43600 to the suction port of the J 45268-4 flush adapter. 11. Flush the front A/C system. Follow the instructions supplied with the J 43600. Close the valve on the external refrigerant tank, before starting the flush process. IMPORTANT: Flush the front A/C system before flushing the auxiliary A/C system. 12. If the vehicle is equipped with rear A/C, flush the auxiliary A/C system separately. 13. Cut the orifice tube frame and screen, enough to access the end of the orifice tube Pinch off the orifice tube. IMPORTANT: Pinch off the orifice tube in order to prevent refrigerant flow to the front system during the auxiliary system flush. 14. Install the pinched orifice tube. 15. Remove the auxiliary TXV. 16. Install the J 45268-104. IMPORTANT: The auxiliary evaporator core can be flushed without totally reassembling into the auxiliary HVAC module. 17. Install the auxiliary evaporator core to the A/C lines. 18. Raise the vehicle. Refer to Lifting and Jacking the Vehicle on page. 19. Connect the auxiliary A/C lines to the auxiliary evaporator core. 20. Lower the vehicle. 21. Flush the auxiliary A/C system. Follow the instructions supplied with the J 43600. 22. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 23. Remove the auxiliary A/C lines from the auxiliary evaporator core. 24. Lower the vehicle. 25. Remove the J 45268-104. 26. Inspect the TXV for debris. Clean or replace as needed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 3042 27. Install the auxiliary TXV. 28. Remove the J 45268-4 from the A/C compressor suction hose. 29. Remove the J 45268-5 from the A/C compressor discharge hose. - Drain the PAG oil from the A/C compressor, through the suction and discharge ports. - Rotate the compressor input shaft to assist in draining the PAG oil from the A/C compressor. 30. Install the A/C compressor. 31. Install a new orifice tube. 32. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. IMPORTANT: Flushing will remove all of the PAG oil from the A/C system. 33. Add the total system capacity of PAG oil to the A/C system. Refer to Refrigerant System Capacities. IMPORTANT: Flushing will remove the fluorescent leak detection dye from the A/C system. 34. Add one bottle of J 41447 using the J 41459. 35. Leak test the fittings using the J 42220. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications If the refrigerant oil was removed from the A/C system during the recovery process or during the component replacement, the refrigerant oil must be replenished. Add the refrigerant oil as indicated. If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. Accumulator ......................................................................................................................................... .......................................................................... 60 ml Compressor .................................................... .............................................................................................................................................................. .. 60 ml Condenser .............................................................................................................................. ........................................................................................ 30 ml Evaporator ........................................ .............................................................................................................................................................. ................ 90 ml Evaporator (Rear) ..................................................................................................... ..................................................................................................... 90 ml Abrupt Loss .......................... .............................................................................................................................................................. ............................ 90 ml NOTE: Replacement compressors do not have any oil in the compressor. Add the correct amount of oil to the replacement compressor before replacement. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 3049 Refrigerant Oil: Fluid Type Specifications Internal Lubricant ............................................................................................................................. Poly-Alkaline Glycol (PAG) Synthetic Refrigerant Oil Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure W/JL4 ABS Automated Bleed Procedure (W/JL4) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: This procedure is ONLY to be performed on vehicles equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding before proceeding. 1. Install a scan tool. 2. Apply the park brake fully. 3. Start the engine and allow the engine to idle. 4. Depress the brake pedal firmly and maintain steady pressure on the pedal. 5. From the VSES Special Functions menu on the scan tool, select the Automated Bleed procedure. 6. Send the automated bleed command by pressing the On key on the scan tool. After initiating the automated bleed procedure, the brake pedal will drop and then pulse back up, 8 times, while the LPA is being purged of any trapped air. 7. Fill the brake master cylinder reservoir with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half full during this bleeding procedure and add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, when cap removal is necessary. 8. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 9. Install a transparent hose over the end of the bleeder valve. 10. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container. 11. Have an assistant slowly depress the brake pedal and maintain pressure on the pedal. 12. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 13. Tighten the bleeder valve when full brake pedal travel has occurred. 14. Have the assistant slowly release the brake pedal. Wait 5 seconds before proceeding to the next step. 15. Repeat steps 11-14 until all air is purged from the same wheel hydraulic circuit. 16. After all air has been purged from the right rear hydraulic circuit and the bleeder valve is tightened securely, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 17. Repeat steps 9-15 at the left rear wheel hydraulic circuit. 18. After all air has been purged from the right rear hydraulic circuit and the bleeder valve is tightened securely, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 19. Repeat steps 9-15 at the right front wheel hydraulic circuit. 20. After all air has been purged from the right rear hydraulic circuit and the bleeder valve is tightened securely, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 21. Repeat steps 9-15 at the left front wheel hydraulic circuit. 22. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container. 23. Install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 24. Install a transparent hose over the end of the bleeder valve. 25. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container. 26. Use the procedure below to purge the Medium Pressure Accumulator (MPA) of any trapped air. 26.1. With the engine still idling, select the Bleed MPA procedure from the VSES Special Functions menu. 26.2. Send the bleed MPA command by pressing the On key on the scan tool. 26.3. Open the LEFT FRONT wheel hydraulic circuit bleeder valve. Important: Ensure that you fully release the brake pedal for at least 2 seconds between pedal strokes. The amount of accumulated time between pedal strokes is calculated to deliver the most thorough bleed of the Medium Pressure Accumulator (MPA). 26.4. Depress the brake pedal as far as possible using a smooth stroke. 26.5. Release the brake pedal using a smooth stroke. 26.6. Repeat steps 26.4-26.5 until 13 complete pedal strokes have been performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3054 Important: Observe the MPA switch parameter as the pedal strokes are being performed. The MPA switch parameter should change from Uncharged to Charged several times during the first 8 or 9 strokes. After approximately 10 pedal strokes, the MPA switch parameter should remain Charged. If the parameter does not change, repeat all of step 26. 26.7. The valves within the BPMV are active for the first 13 complete pedal strokes to enable the MPA to be filled and discharged, forcing any trapped air out of the LEFT FRONT wheel hydraulic circuit bleeder valve. 26.8. Continue to depress and release the brake pedal while observing the fluid within the transparent hose. When no air is observed exiting the hydraulic system, proceed to the next step. 26.9. Depress the brake pedal and maintain pedal position. 26.10. Have an assistant tighten the bleeder valve. 26.11. Release the brake pedal. 27. Remove the scan tool from the vehicle. 28. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container. 29. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 30. If the brake pedal feels spongy, repeat this entire bleed procedure. If the brake pedal still feels spongy after repeating this procedure, inspect the brake system for external leaks. 31. Observe the brake warning indicator to determine whether or not the indicator remains illuminated. 32. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. W/O JL4 ABS Automated Bleed Procedure (w/o JL4) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: This procedure may be performed on all vehicles EXCEPT those equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. 15. Drive the vehicle to exceed 13 kPa (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3055 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Manual Hydraulic Brake System Bleeding (Manual) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder- loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely- after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely- after all air has been purged from the left rear hydraulic circuit- install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely- after all air has been purged from the right front hydraulic circuitinstall a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3056 Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Pressure Hydraulic Brake System Bleeding (Pressure) Tools Required ^ J29532 Diaphragm Type Brake Pressure Bleeder, or equivalent ^ J35589-A Brake Pressure Bleeder Adapter Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder- after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J29532, or equivalent. Add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J29532, or equivalent, to the J35589-A. 8. Charge the J29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit- install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuitinstall a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3057 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J35589-A. 23. Remove the J35589-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3058 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the fuse block. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Disconnect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 7. Access the IP module yellow 2-way connector (1) located behind the IP module (2) by removing the upper IP trim panel. Refer to Trim Pad Replacement - IP Upper in Instrument Panel, Gauges and Warning Indicators. 8. Remove the CPA from the IP module yellow 2-way connector (1) located behind the IP module (2). 9. Disconnect the IP module yellow 2-way connector (1) located behind the IP module (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 3063 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the IP module yellow 2-way connector (1) located behind the main IP support. 3. Install the CPA to the IP module yellow 2-way connector (1) located behind the main IP support. 4. Connect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 5. Install the CPA (1) to the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Install the AIR BAG Fuse to the fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - SIR if the AIR BAG indicator does not operate as described. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View Fuse: Locations Fuse Block - Underhood Connector View Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 3071 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 3072 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 3073 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 3074 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 3075 Fuse: Locations Fuse Block - Underhood Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 3076 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 3077 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Fuse: Application and ID Fuse Block - Underhood Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 3080 Fuse Application Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 3081 Fuse Application Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 3082 Fuse Block - Right I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 3083 Fuse: Application and ID Fuse Block - Left I/P Fuse Block - Left I/P Fuse Block Fuse Applications Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 3084 Fuse Block Fuse Applications Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - Location Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 3089 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 3090 Fuse Block: Locations Fuse Block - Underhood Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 3091 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 3092 Fuse Block: Locations Fuse Block - Underhood Connector View Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 3093 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 3094 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 3095 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P Fuse Block: Diagrams Fuse Block - Left I/P Fuse Block - Left I/P Fuse Block Fuse Applications Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3098 Fuse Block Fuse Applications Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3099 Fuse Block - Right I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3100 Fuse Block: Diagrams Fuse Block - Underhood Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3101 Fuse Application Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3102 Fuse Application Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3103 Fuse Block: Diagrams Left I/P Fuse Block - Left I/P - C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3104 Fuse Block - Left I/P - C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3105 Fuse Block - Left I/P - C1 Part 3 Fuse Block - Left I/P - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3106 Fuse Block - Left I/P - C4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3107 Fuse Block - Left I/P - C6 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3108 Fuse Block: Diagrams Fuse Block - Left I/P Fuse Block Fuse Applications Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3109 Fuse Block Fuse Applications Part 2 Fuse Block - Right I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3110 Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3111 Fuse Application Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3112 Fuse Application Part 2 Left I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3113 Fuse Block - Left I/P - C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3114 Fuse Block - Left I/P - C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3115 Fuse Block - Left I/P - C1 Part 3 Fuse Block - Left I/P - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3116 Fuse Block - Left I/P - C4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3117 Fuse Block - Left I/P - C6 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Relay Block Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3118 Relay Block - Body - C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3119 Relay Block - Body - C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3120 Relay Block - Body - C1 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3121 Relay Block - Body - C2 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3122 Relay Block - Body - C2 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3123 Relay Block - Body - C2 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3124 Relay Block - Body - C4 Relay Block - Body - C5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3125 Relay Block - Body - C6 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3126 Relay Block - Body - C6 Part 2 Relay Block - Body - C8 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3127 Relay Block - Body - C9 Relay Block - Body - C10 Part 1 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3128 Relay Block - Body Right I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3129 Fuse Block - Right I/P - C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3130 Fuse Block - Right I/P - C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3131 Fuse Block - Right I/P - C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3132 Fuse Block - Right I/P - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3133 Fuse Block - Right I/P - C4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3134 Fuse Block - Right I/P - C5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3135 Fuse Block - Right I/P - C6 Fuse Block - Right I/P - C7 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3136 Fuse Block - Right I/P - C7 Part 2 Fuse Block - Right I/P - C8 Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3137 Relay Block - Underhood - C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3138 Relay Block - Underhood - C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3139 Relay Block - Underhood - C1 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3140 Relay Block - Underhood - C2 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3141 Relay Block - Underhood - C2 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3142 Relay Block - Underhood - C2 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3143 Relay Block - Underhood - C2 Part 4 Relay Block - Underhood - C3 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3144 Relay Block - Underhood - C3 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3145 Relay Block - Underhood - C4 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3146 Relay Block - Underhood - C4 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3147 Relay Block - Underhood - C4 Part 3 Relay Block - Underhood - C5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3148 Relay Block - Underhood - C6 Relay Block - Underhood - C7 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 3149 Relay Block - Underhood - C8 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P Fuse Block: Application and ID Fuse Block - Left I/P Fuse Block - Left I/P Fuse Block Fuse Applications Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P > Page 3152 Fuse Block Fuse Applications Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P > Page 3153 Fuse Block - Right I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P > Page 3154 Fuse Block: Application and ID Fuse Block - Underhood Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P > Page 3155 Fuse Application Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P > Page 3156 Fuse Application Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 3159 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the starting and charging center bracket remove the 4 retaining bolts (1). 10. Remove the starting and charging center bracket assembly from the fender. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 3160 INSTALLATION PROCEDURE 1. Install the starting and charging center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 3161 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 3162 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 3163 Fuse Block: Service and Repair I/P Electrical Center or Junction Block Replacement Left REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the left side end panel. 3. Press on the clips on the top and the bottom in order to remove the fuse block from the instrument panel (IP) assembly. 4. Disconnect all wiring connectors from the fuse block. 5. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Connect all wiring connectors to the fuse block. 2. Position the fuse block onto the IP assembly. 3. Press on the clips on the top and the bottom of the fuse block and push in the clips until seated. 4. Install the left side end panel. 5. Connect the negative battery cable(s). Right REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 3164 CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the right side end panel. 3. Unclip the wiring connector(s) from the front of the Instrument Panel (IP) wiring harness junction block Unclip the harness from the fastener. 4. Remove the IP wiring harness junction block from the IP by pressing on both of the clips and pulling rearward. 5. Disconnect the lower IP light bulb by twisting the bulb counterclockwise and pulling the bulb rearward. 6. Feed the IP wiring harness junction block through the hole in the IP. 7. Disconnect all remaining wiring connectors from the rear of the IP wiring harness junction block. 8. Remove the IP wiring harness junction block from the vehicle. INSTALLATION PROCEDURE 1. Connect the wiring connectors to the rear of the IP wiring harness junction block. 2. Feed the IP wiring harness junction block through the hole in the IP. 3. Connect the lower IP light bulb by twisting the bulb socket clockwise while pushing in. 4. Connect the IP wiring harness junction block to the IP by pressing on both clips and pushing until sealed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 3165 5. Connect the wiring connector(s) onto the front of the IP wiring harness junction block and connect the harness to the fastener. 6. Install the right side end panel. 7. Connect the negative battery cable(s). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 3166 Fuse Block: Service and Repair Body Wiring Harness Junction Block Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the harness from the front of the body wiring harness junction block. 3. Unsnap the cover from the body wiring harness junction block. 4. Unsnap the top pivots and rotate the body wiring harness junction block (1) down. Unsnap the lower pivots and remove the body wiring harness junction block from the bracket (2). 5. Disconnect the two 68-way IP connectors. 6. Disconnect the remaining wiring connectors from the body wiring harness junction block. 7. Remove the body wiring harness junction block from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 3167 1. Connect the two 68-way IP connectors to the body wiring harness junction block. 2. Connect all remaining wiring connectors. 3. Snap the body wiring harness junction block (1) onto the bracket (2). 4. Connect the harness to the front of the body wiring harness junction block. 5. Fasten the cover to the body wiring harness junction block. 6. Connect the negative battery cable(s). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 3171 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Junction Block - Rear Lamps - C2 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 3172 Junction Block - Rear Lamps - C2 Part 2 Junction Block - Rear Lamps - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 3173 Junction Block - Rear Lamps - C4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) Relay Box: Service and Repair Relay Replacement (Within an Electrical Center) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views to locate the electrical center where the relay exists. IMPORTANT: Always note the orientation of the relay. - Make sure the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). NOTE: Use J 43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 3176 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 3177 Relay Box: Service and Repair Relay Replacement (Attached to Wire Harness) REMOVAL PROCEDURE 1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. IMPORTANT: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). INSTALLATION PROCEDURE 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Always On CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. MIL OPERATION The MIL is located on the instrument panel (IP). MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. ^ The MIL illuminates during a bulb test and a system test. ^ A DTC will be stored if a MIL is requested by the diagnostic. MIL ILLUMINATION ^ The MIL will illuminate with ignition switch ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Intermittent Conditions TEST DESCRIPTION Steps 1-6 The number below refers to the step numbers on the diagnostic table. 2. The step determines if the condition is with the MIL control circuit or the PCM. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 3183 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Inoperative CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. There should be a steady MIL with the ignition ON and the engine OFF. MIL OPERATION The MIL is located on the instrument panel (IP). MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. ^ The MIL illuminates during a bulb test and a system test. ^ A DTC will be stored if a MIL is requested by the diagnostic. MIL ILLUMINATION ^ The MIL will illuminate with ignition switch ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Intermittent Conditions TEST DESCRIPTION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 3184 Steps 1-14 The numbers below refer to the step numbers on the diagnostic table. 3. This step determines if the condition is with the MIL control circuit or the PCM. 4. This step determines if a voltage is being applied to the control circuit. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair How to Reset the CHANGE ENGINE OIL Message The GM "Oil Life System" calculates when to change your engine oil and filter based on vehicle use. Anytime your oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where you change oil prior to a CHANGE ENGINE OIL message being turned on, reset the system. To reset the CHANGE ENGINE OIL message do the following: 1. Turn the ignition key to the RUN with the engine off. 2. Fully press and release the accelerator pedal three times within five seconds. If the CHANGE ENGINE OIL message flashes for 5 seconds, the system is reset. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Tire/Wheel - Spare Tire Is Non-Matching To Other Tires Spare Tire: Technical Service Bulletins Tire/Wheel - Spare Tire Is Non-Matching To Other Tires INFORMATION Bulletin No.: 02-03-10-001E Date: November 01, 2010 Subject: Spare Tire is a Different Size than Other Tires Models: 2002-2011 Cadillac Escalade Models 1999-2007 Chevrolet Silverado (Classic) 2000-2011 Chevrolet Suburban, Tahoe 2002-2011 Chevrolet Avalanche 1999-2007 GMC Sierra (Classic) 2001 GMC Sierra C3 2001-2011 GMC Yukon Models 2002-2011 GMC Sierra Denali Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-03-10-001D (Section 03 - Suspension). This bulletin is being issued to supply additional information concerning the spare tire on the above vehicles. You or your customers may have noticed that the spare tire has a 16-inch diameter steel wheel or 17-inch diameter aluminum wheel while the road tires have a 17-inch, 18-inch, 20-inch or 22-inch diameter aluminum wheel. Although the spare tire has a different wheel diameter and may be a different brand, the rolling circumference is nearly identical to the road tires. The size difference will not cause a concern because the spare and the other tires will travel the same distance in one revolution. This combination of non-matching tires is used most often on full-size trucks. These vehicles use a road tire and wheel combination that may be too large to conveniently fit the storage compartment space of the vehicle. The customer may not be able to easily remove the spare tire/wheel from the storage area because of its size and/or weight. A steel spare wheel, rather than an aluminum one, may be used since the spare is stowed under the vehicle where it is exposed to road and weather elements. A steel wheel is less likely to incur cosmetic damage while in the stowed position for long periods of time. Please provide this information to your customers. Also, remind your customers of the importance of following the tire maintenance schedule as listed in their Owner Manual. Additional tire care information can be found by visiting www.gmtiresafety.com or contacting GM toll-free. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3221 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3222 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3223 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 3228 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3233 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3234 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3235 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration Wheels: Customer Interest Wheels/Tires - Slow Tire Leak/Vibration Bulletin No.: 03-03-10-001D Date: January 17, 2008 TECHNICAL Subject: Tire Slowly Goes Flat and/or Excessive wheel Vibration Caused By Bead Splits (Replace wheels with New Heavy Duty Rim Version) Models: 1999-2006 Chevrolet Silverado 1500 Series Pickup Models (Classic) 1999-2006 Chevrolet Express 1500 Series Vans 2000-2006 Chevrolet Suburban Tahoe 1999-2006 GMC Sierra 1500 Series Pickup Models (Classic) 1999-2006 GMC Savana 1500 Series Vans 2002-2006 GMC Yukon Yukon XL 2007 GMC Sierra Denali Crew Cab with 6-Bolt, 16 X 6.5 Full Face Steel wheel (Base and RPO PY2) Supercede: This bulletin is being revised to add the Express and Savana models and add information to the Correction section. Please discard Corporate Bulletin Number 03-03-10-001C (Section 03 Suspension). Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on a tire that slowly goes flat and/or excessive wheel vibration. This condition is more apparent on vehicles in which customer usage typically involves frequent severe conditions such as: High load (at or above gross vehicle weight) Rough road/off road usage Fleet/Commercial usage Cause The wheel may experience a crack or split in the outboard bead seat weld area. A weld attaches the rim and disc together on full-face wheels in this area. To identify this wheel it is offered in a silver painted version P/N 9593915 code "TZA" and a chrome-clad version, P/N 9593150 code "RSC" (these codes are stamped into the wheel's disc near the bolt holes). Correction Wheel replacement should only be done for air loss and/or vibration caused by bead splits. A new heavy-duty rim version of these wheels has been released for service. The new heavy-duty painted wheel is P/N 9595245 code "FFU" used as a road wheel and spare. The new heavy-duty chrome clad version is P/N 9595306 code "FFW" used as a road wheel only (these codes are stamped into the inboard rim flange balance weight area and are also on a sticker near the bolt holes). If a condition of a crack or split as described above occurs all (5) five of the original wheels on the vehicle should be replaced with the new heavy-duty wheels as follows: Replace road wheel P/N 9593915 with P/N 9595245. Replace road wheel PIN 9593150 with P/N 9595306. Replace the spare wheel with P/N 9595245 on all vehicles. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration > Page 3240 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3246 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3247 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3248 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 3253 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3258 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3259 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3264 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3265 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3266 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 3271 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3276 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3277 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3278 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration Wheels: All Technical Service Bulletins Wheels/Tires - Slow Tire Leak/Vibration Bulletin No.: 03-03-10-001D Date: January 17, 2008 TECHNICAL Subject: Tire Slowly Goes Flat and/or Excessive wheel Vibration Caused By Bead Splits (Replace wheels with New Heavy Duty Rim Version) Models: 1999-2006 Chevrolet Silverado 1500 Series Pickup Models (Classic) 1999-2006 Chevrolet Express 1500 Series Vans 2000-2006 Chevrolet Suburban Tahoe 1999-2006 GMC Sierra 1500 Series Pickup Models (Classic) 1999-2006 GMC Savana 1500 Series Vans 2002-2006 GMC Yukon Yukon XL 2007 GMC Sierra Denali Crew Cab with 6-Bolt, 16 X 6.5 Full Face Steel wheel (Base and RPO PY2) Supercede: This bulletin is being revised to add the Express and Savana models and add information to the Correction section. Please discard Corporate Bulletin Number 03-03-10-001C (Section 03 Suspension). Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on a tire that slowly goes flat and/or excessive wheel vibration. This condition is more apparent on vehicles in which customer usage typically involves frequent severe conditions such as: High load (at or above gross vehicle weight) Rough road/off road usage Fleet/Commercial usage Cause The wheel may experience a crack or split in the outboard bead seat weld area. A weld attaches the rim and disc together on full-face wheels in this area. To identify this wheel it is offered in a silver painted version P/N 9593915 code "TZA" and a chrome-clad version, P/N 9593150 code "RSC" (these codes are stamped into the wheel's disc near the bolt holes). Correction Wheel replacement should only be done for air loss and/or vibration caused by bead splits. A new heavy-duty rim version of these wheels has been released for service. The new heavy-duty painted wheel is P/N 9595245 code "FFU" used as a road wheel and spare. The new heavy-duty chrome clad version is P/N 9595306 code "FFW" used as a road wheel only (these codes are stamped into the inboard rim flange balance weight area and are also on a sticker near the bolt holes). If a condition of a crack or split as described above occurs all (5) five of the original wheels on the vehicle should be replaced with the new heavy-duty wheels as follows: Replace road wheel P/N 9593915 with P/N 9595245. Replace road wheel PIN 9593150 with P/N 9595306. Replace the spare wheel with P/N 9595245 on all vehicles. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration > Page 3287 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3293 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3294 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3295 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 3300 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3305 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3306 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 3311 Wheels: Testing and Inspection Wheel Mounting Surface Check Replace any wheels that are bent or dented, or have excessive lateral or radial runout. Wheels with runout greater than specified may cause objectionable vibrations. 1. Use a straight edge 203 - 229 mm (8 - 9 inch) long. Place the straight edge on the wheel inboard mounting surface. Try to rock the straightedge up and down within the mounting surface. 2. Repeat this procedure on at least 3-4 different positions on the inboard mounting surface. ^ The outer ring of the mounting surface normally is raised above everything inside the mounting surface. ^ The mounting surface will be raised above the outer ring if the wheel mounting surface has been bent on a tire changer. ^ If you can rock the straight edge, the mounting surface is bent and you must replace the wheel. 3. Inspect the mounting wheel/nut holes for damage caused from over-torquing the wheel/nuts. Inspect for collapsed wheel/nut bosses. Inspect for cracked wheel bosses. Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components ^ Adverse vehicle steering stability caused by the modified scrub radius Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 3312 ^ Damage to the vehicle caused by the modified ground clearance ^ Speedometer and odometer inaccuracy Important: ^ Replacement wheels must be equivalent to the original equipment wheels in the following ways: The load capacity - The wheel diameter - The rim width - The wheel offset - The mounting configuration ^ A wheel of the incorrect size or type may affect the following conditions: Wheel and hub-bearing life - Brake cooling - Speedometer/odometer calibration - Vehicle ground clearance - Tire clearance to the body and the chassis 4. Replace the wheel if the wheel is bent. 5. Replace the wheel if the wheel/nut boss area is cracked. Identify steel wheels with a 2 or 3-letter code stamped into the rim near the valve stem. Aluminum wheels have the code, the part number, and the manufacturer identification cast into the back side of the wheel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair Repair Instructions 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. Important: Do not damage the exterior surface of the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 8. Use general purpose cleaner such as EMS, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 3315 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing A protective clear coating covers the surface of original equipment cast aluminum wheels. A surface degradation may develop if frequent automatic car wash cleaning wears off the factory applied protective clear coating. This can happen at some automatic car wash facilities that use aggressive brushes to clean whitewalls and tires. Once you damage the protective clear coating, exposure to caustic cleaners and road salt can cause further surface deterioration. Damage to the protective clear coating is corrected by replacing the damaged wheel. Refinishing is no longer recommended. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 3316 Wheels: Service and Repair Tire and Wheel Removal and Installation Tire and Wheel Removal and Installation Tools Required ^ J39544-KIT Complete Torque Socket Set Caution: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident. Notice: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. Important: Removing wheels can be difficult because of foreign material or a tight fit between the wheel center hole and the hub or rotor. Excessive force, such as hammering on the wheel or tire, can cause damage. Slightly tapping the tire side wall with a rubber mallet is acceptable. 1. Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut two turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. Removal Procedure 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel nuts from the tire and wheel. 3. Mark the location of the tire and wheel to the hub assembly. 4. Remove the tire and wheel from the vehicle. 5. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 3317 Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. Notice: A torque wrench or J39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. 1. Install the tire and wheel. Align the locating mark of the tire and wheel to the hub. Notice: Refer to Fastener Notice in Service Precautions. Important: Tighten the nuts evenly and alternately in order to avoid excessive runout. 2. Install the wheel nuts. Tighten the wheel nuts as shown to 190 Nm (140 ft. lbs.). 3. Remove the safety stands. 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Drive Train - Revised Wheel Bearing Adjustment Procedure Wheel Bearing: Technical Service Bulletins Drive Train - Revised Wheel Bearing Adjustment Procedure File In Section: 04 - Driveline Axle Bulletin No.: 02-04-20-002 Date: May, 2002 SERVICE MANUAL UPDATE Subject: Revised Wheel Bearing Adjustment Procedure Models: 2001-2002 Chevrolet and GMC C/K and G-Van Models with 10.5 and 11.5 Inch Axles This bulletin is being issued to revise the Wheel Bearing Adjustment procedure in the Rear Drive Axle sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within Service Information (SI). If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Wheel Bearing Adjustment Preliminary Inspection Important: Ensure the brakes are fully released and do not drag. Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement. 3. Remove the hub adjuster nut retaining ring. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Drive Train - Revised Wheel Bearing Adjustment Procedure > Page 3322 4. Remove the adjuster nut lock key. Notice: Refer to Fastener Notice in Cautions and Notices. 5. Tighten the wheel bearing adjusting nut using the J 2222-C. Rotate the hub in the opposite direction to the way the adjuster nut is turning. Ensure the inner bearing and the seal seats against the spindle shoulder. Tighten Tighten the adjusting nut to 70 N.m (52 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Drive Train - Revised Wheel Bearing Adjustment Procedure > Page 3323 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. Important: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. 9. Install the retaining ring. 10. Install the axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement. 11. Inspect the lubricant level and add, if necessary. Refer to Lubricant Level Check. 12. Lower the vehicle. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 3324 Wheel Bearing: Service and Repair "For information regarding this component please refer to wheel hub service and repair" Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Wheels - Correct Hub Cap Installation Procedure Wheel Cover: Technical Service Bulletins Wheels - Correct Hub Cap Installation Procedure Bulletin No.: 03-03-10-002B Date: November 02, 2005 INFORMATION Subject: Use of Correct Installation Procedure for Loose Hubcap Assembly Models: 1998-2006 Chevrolet Express Van 1999-2006 Chevrolet Silverado Models 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1998-2006 GMC Savana Van 1999-2006 GMC Sierra Models 2000-2006 GMC Yukon, Yukon XL Models Supercede: This bulletin is being revised to add the 2006 model year. Please discard Corporate Bulletin Number 03-03-10-002A (Section 03 - Suspension). Some hubcap assemblies on the above-listed vehicles are being returned to the Warranty Parts Center (WPC) for loose and/or rattle conditions. Some returned hubcaps have the stand-off insulators removed. Analyses of these parts show no out of specification condition. Hubcap assemblies are placed in the vehicle by the assembly plant for dealer installation. Installation is done by threading the six or eight plastic nut caps, which are part of the hubcap assembly, to the external threads of the wheel (lug) nuts. If over-tightened, these plastic nut caps will jump threads, as designed, causing a loose or rattle condition. Important: ^ DO NOT over-tighten the plastic nut caps. ^ DO NOT use an impact wrench on the plastic nut caps. ^ DO NOT modify or remove the stand-off insulators from the plastic hubcap assembly. The nut cap system is designed to skip a thread if over-tightened. DO NOT replace the hubcap assembly if this happens. Hold hubcap (2) firmly in place on wheel with the plastic wheel nut caps (3) aligned with the steel wheel nuts (1). Hand snug each nut cap (3) (using a hand held deep socket or torque stick) until fully seated against the hubcap (2). You should feel the nut cap (3) ratchet against the hubcap (2) a couple times as the nut cap (3) seats. After all nut caps (3) have been seated, check tightness of each nut cap (3) using the socket or torque stick and tighten any nut cap (3) that may have loosened. If a nut cap (3) jumps thread (a design feature to prevent damage) and becomes loose during tightening, continue to tighten and stop short of thread jump. Follow the installation instruction sheet that is included in each hubcap package. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Wheels - Correct Hub Cap Installation Procedure > Page 3329 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Shaft Nut ............................................................................................................................ ................................................ 210 Nm (155 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 3342 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 3348 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Nut Torque Wheel Fastener: Specifications Wheel Nut Torque Single Wheel Nuts ............................................................................................................................... ................................................. 190 Nm (140 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Nut Torque > Page 3351 Lug Nut Torque Patterns Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Wheel Stud Replacement Tools Required ^ J43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the wheel stud from the hub flange using the J43631. 5. Remove the wheel stud from the hub flange. Installation Procedure 1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange. 4. Tighten the lug nut until the stud contacts the back of the hub flange. 5. Remove the wheel nut. 6. Remove the washers. 7. Install the brake rotor. 8. Install the tire and wheel. 9. Remove the safety stands. 10. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 3354 Wheel Fastener: Service and Repair Rear Wheel Stud Replacement Tools Required ^ J43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. 4. Remove the wheel stud from the axle flange using the J43631 for the 15 series. 5. Remove the axle shaft for vehicles with 9.5 inch ring gear. 6. Remove the rear hub assembly for vehicles with 10.5 in ring gear. 7. Remove the wheel stud from the axle flange using the J43631. 8. Remove the wheel stud from the hub flange using the J43631. Installation Procedure 1. Install the stud into the axle flange for the 15 Series. 2. Install the 4 washers and the lug nut to the stud. 3. Tighten the lug nut in order to draw the stud into the flange until the stud fully seats. 4. Remove the lug nut and the washers. 5. Install the axle shaft for the vehicles with 9.5 in ring gear. 6. Install the rear hub assembly for the vehicles with 10.5 in ring gear. 7. Install the rotor. 8. Install the tire and wheel. 9. Remove the safety stands. 10. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Service and Repair Wheel Seal: Service and Repair "For information regarding this component please refer to wheel hub service and repair" Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1035 x 70% = 725) (150 x 70% = 105). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis > Engine Compression Test (Electronic Throttle) Compression Check: Testing and Inspection Engine Compression Test (Electronic Throttle) Engine Compression Test (Electronic Throttle) 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gauge at zero and crank the engine through four compression strokes, four puffs. 8. Check the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml. (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Recheck the compression and record the reading. 10. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1035 x 70% = 725) (150 x 70% = 105). Normal-Compression builds up quickly and evenly to the specified compression for each cylinder. - Piston Rings Leaking-Compression is low on the first stroke. Then compression builds up with the following strokes but does not reach normal. Compression improves considerably when you add oil. - Valves Leaking-Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. - If two adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis > Engine Compression Test (Electronic Throttle) > Page 3365 Compression Check: Testing and Inspection Engine Compression Test (Mechanical Throttle) Engine Compression Test (Mechanical Throttle) 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Block the throttle plate wide open. 6. Start with the compression gauge at zero and crank the engine through four compression strokes, four puffs. 7. Make the compression check for each cylinder. Record the reading. 8. If a cylinder has low compression, inject approximately 15 ml. (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Recheck the compression and record the reading. 9. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1035 x 70% = 725) (150 x 70% = 105). Normal-Compression builds up quickly and evenly to the specified compression for each cylinder. - Piston Rings Leaking-Compression is low on the first stroke. Compression then builds up with the following strokes but does not reach normal. Compression improves considerably when you add oil. - Valves Leaking-Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. - If two adjacent cylinders have lower than normal compression and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Engine Mechanical Specifications Camshaft: Specifications Engine Mechanical Specifications Camshaft Camshaft End Play ........................................................................................................................................................ 0.025-0.305 mm (0.001-0.012 inch) Camshaft Journal Diameter ........................................................................................................................................... 54.99-55.04 mm (2.164-2.166 inch) Camshaft Journal Diameter Out-of-Round ........................................................................................................................................ 0.025 mm (0.001 inch) Camshaft Lobe Lift (Intake) ............................................................................................. ................................................................... 6.82 mm (0.268 inch) Camshaft Lobe Lift (Exhaust) .............................................................................................................................................................. 6.96 mm (0.274 inch) Camshaft Runout (Measured at the Intermediate Journals) ................................................................................................................. 0.05 mm (0.002 inch) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Engine Mechanical Specifications > Page 3371 Camshaft: Specifications Fastener Tightening Specifications Camshaft Retainer Bolt ....................................................................................................................... ...................................................... 25 Nm (18 ft. lbs.) Camshaft Sensor Bolt ..................................... .......................................................................................................................................... 25 Nm (18 ft. lbs.) Camshaft Sprocket Bolt ........................................................................................................... ................................................................. 35 Nm (28 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 3372 Camshaft: Service and Repair Camshaft Replacement Removal Procedure 1. Raise the hood to the servicing position, perform the following: - Remove the hood hinge bolts (1). - Raise the hood until vertical. - Install the hood hinge bolts until snug in the service position (2). 2. Remove the radiator support. 3. Remove the timing chain and camshaft sprocket. 4. Remove the valve lifters from both cylinder heads. 5. Remove the camshaft sensor bolt and sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 3373 6. Remove the camshaft retainer bolts and retainer. Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 7. Remove the camshaft. 7.1. Install three M8-1.25 x 100 mm (M8-1.25 x 4.0 inch) bolts to the bolt holes in the front of the camshaft. 7.2. Using the bolts as a handle, carefully rotate and pull the camshaft out of the engine block. 7.3. Remove the three bolts from the camshaft. 8. Clean and inspect the camshaft and bearings. Installation Procedure Important: If camshaft replacement is required, the valve lifters must also be replaced. 1. Lubricate the camshaft journals and the bearings with clean engine oil. 2. Install three M8-1.25 x 100 mm (M8-1.25 x 4.0 inch) bolts to the bolt holes in the front of the camshaft. Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 3. Using the bolts as a handle, carefully install the camshaft into the engine block. 4. Remove the three bolts from the front of the camshaft. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 3374 Important: Install the retainer plate with the sealing gasket facing the engine block. The gasket surface on the engine block should be clean and free of dirt and/or debris. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the camshaft retainer and bolts. - Tighten the camshaft retainer bolts to 25 Nm (18 ft. lbs.). 6. Inspect the camshaft sensor O-ring seal. If the O-ring seal is not cut or damaged, it may be reused. 7. Lubricate the O-ring seal with clean engine oil. 8. Install the camshaft sensor and bolt. - Tighten the camshaft sensor bolt to 25 Nm (18 ft. lbs.). 9. Install the timing chain and camshaft sprocket. 10. Install the valve lifters. 11. Install the radiator support. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 3375 12. Remove the hood hinge bolts from the service position (2). 13. Lower the hood to the normal position. 14. Install the hood hinge bolts. - Tighten the hood hinge bolts to 25 Nm (18 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Valve Lifter Guide Bolt ......................................................................................................................... .............................................. 12 Nm (106 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 3379 Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement - Tools Required J 3049-A Valve Lifter Remover Removal Procedure 1. Remove the cylinder head and gasket. 2. Remove the valve lifter guide bolts (1). 3. Remove the valve lifters and guide. Important: Some valve lifters may be stuck in their bores because of gum or varnish deposits. 4. Use J 3049-A or equivalent in order to remove the valve lifters (if required). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 3380 5. Remove the valve lifters from the guide. 6. Organize or mark the components so that they can be installed in the same location from which they were removed. 7. Clean and inspect the valve liners. Installation Procedure Important: When reusing valve lifters, install the lifters to their original locations. 1. Lubricate the valve lifters and engine block valve lifter bores with clean engine oil. 2. Insert the valve lifters into the lifter guides. Align the flat area on the top of the lifter with the flat area in the lifter guide bore. Push the lifter completely into the guide bore. 3. Install the valve lifters and guide to the engine block. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the valve lifter guide bolt (1). - Tighten the valve lifter guide bolt (1) to 12 Nm (106 inch lbs.). 5. Install the cylinder head and gasket. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair Push Rod: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the valve rocker arm cover. Important: Place the valve rocker arms, pushrods, and pivot support, in a rack so that the can be installed in the same location from which they were removed. 2. Remove the valve rocker arm bolts. 3. Remove the valve rocker arms. 4. Remove the valve rocker arm pivot support. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 3384 5. Remove the pushrods. 6. Clean and inspect the valve rocker arms and pushrods. Installation Procedure Important: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. 1. Lubricate the valve rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the valve rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the valve rocker arm. 3. Install the valve rocker arm pivot support. Important: Make sure that the pushrods seat properly to the valve lifter sockets. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 3385 4. Install the pushrods. Important: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. 5. Install the rocker arms and bolts. 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The engine firing order is 1,8,7,2,6,5,4,3. Cylinders 1,3,5 and 7 are the left bank. Cylinder 2,4,6 and 8 are the right bank. Notice: Refer to Fastener Notice in Service Precautions. 7. With the engine in the number one firing position, tighten the following valve rocker arm bolts: - Tighten the cylinders 1,2,7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). - Tighten the cylinders 1,3,4 and 5 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following valve rocker arm bolts: - Tighten the cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). - Tighten the cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 10. Install the valve rocker arm cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 02-06-01-029 > Sep > 02 > Engine - Needle Bearings Found Upon Oil Change Rocker Arm Assembly: Customer Interest Engine - Needle Bearings Found Upon Oil Change File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-029 Date: September, 2002 INFORMATION Subject: Needle Bearings Found in Oil Pan (Replace Rocker Arms) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird 2002 Cadillac Escalade, Escalade EXT 1999-2002 Chevrolet Silverado 2000-2002 Chevrolet Suburban, Tahoe 2002 Chevrolet Avalanche 1999-2002 GMC Sierra 2000-2002 GMC Yukon, Yukon XL 2003 HUMMER H2 with 4.8L, 5.3L, 5.7L or 6.0L V8 Engine (VINs V, T, G, S, U - RPOs LR4, LM7, LS1, L56, L04, L09) Condition Some customers may comment or technicians may notice needle bearings being found during an engine oil change. The bearings may be found in either the drain pan used or on the magnetic oil pan drain plug. Cause One or more rocker arms may have experienced a bearing failure. Correction 1. Inspect all of the rocker arms for bearing retainer cap failure. If one or more defective rocker arms are found, replace all 16 rocker arms. Refer to the Engine Mechanical sub-section in the appropriate Service Manual. 2. If no condition with the rocker arms is found, refer to the service history for previous rocker arm repair. If previous rocker arm repair was made, then the engine may not have been thoroughly cleaned of loose roller bearings. If no previous rocker arm repair was made, then look for another condition. 3. Remove the oil pan and clean out any additional bearings found within the oil pan. Refer to the Engine Mechanical sub-section in the appropriate Service Manual. 4. Install the oil pan. Refer to the Engine Mechanical sub-section in the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 02-06-01-029 > Sep > 02 > Engine - Needle Bearings Found Upon Oil Change > Page 3394 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 02-06-01-029 > Sep > 02 > Engine - Needle Bearings Found Upon Oil Change Rocker Arm Assembly: All Technical Service Bulletins Engine - Needle Bearings Found Upon Oil Change File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-029 Date: September, 2002 INFORMATION Subject: Needle Bearings Found in Oil Pan (Replace Rocker Arms) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird 2002 Cadillac Escalade, Escalade EXT 1999-2002 Chevrolet Silverado 2000-2002 Chevrolet Suburban, Tahoe 2002 Chevrolet Avalanche 1999-2002 GMC Sierra 2000-2002 GMC Yukon, Yukon XL 2003 HUMMER H2 with 4.8L, 5.3L, 5.7L or 6.0L V8 Engine (VINs V, T, G, S, U - RPOs LR4, LM7, LS1, L56, L04, L09) Condition Some customers may comment or technicians may notice needle bearings being found during an engine oil change. The bearings may be found in either the drain pan used or on the magnetic oil pan drain plug. Cause One or more rocker arms may have experienced a bearing failure. Correction 1. Inspect all of the rocker arms for bearing retainer cap failure. If one or more defective rocker arms are found, replace all 16 rocker arms. Refer to the Engine Mechanical sub-section in the appropriate Service Manual. 2. If no condition with the rocker arms is found, refer to the service history for previous rocker arm repair. If previous rocker arm repair was made, then the engine may not have been thoroughly cleaned of loose roller bearings. If no previous rocker arm repair was made, then look for another condition. 3. Remove the oil pan and clean out any additional bearings found within the oil pan. Refer to the Engine Mechanical sub-section in the appropriate Service Manual. 4. Install the oil pan. Refer to the Engine Mechanical sub-section in the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 02-06-01-029 > Sep > 02 > Engine - Needle Bearings Found Upon Oil Change > Page 3400 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 3401 Rocker Arm Assembly: Specifications Valve Rocker Arm Bolt ........................................................................................................................ .................................................... 30 Nm (22 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 3402 Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the valve rocker arm cover. Important: Place the valve rocker arms, pushrods, and pivot support, in a rack so that the can be installed in the same location from which they were removed. 2. Remove the valve rocker arm bolts. 3. Remove the valve rocker arms. 4. Remove the valve rocker arm pivot support. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 3403 5. Remove the pushrods. 6. Clean and inspect the valve rocker arms and pushrods. Installation Procedure Important: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. 1. Lubricate the valve rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the valve rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the valve rocker arm. 3. Install the valve rocker arm pivot support. Important: Make sure that the pushrods seat properly to the valve lifter sockets. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 3404 4. Install the pushrods. Important: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. 5. Install the rocker arms and bolts. 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The engine firing order is 1,8,7,2,6,5,4,3. Cylinders 1,3,5 and 7 are the left bank. Cylinder 2,4,6 and 8 are the right bank. Notice: Refer to Fastener Notice in Service Precautions. 7. With the engine in the number one firing position, tighten the following valve rocker arm bolts: - Tighten the cylinders 1,2,7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). - Tighten the cylinders 1,3,4 and 5 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following valve rocker arm bolts: - Tighten the cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). - Tighten the cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 10. Install the valve rocker arm cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Connecting Rod Bearing Bore Diameter ................................................................................................................... 56.505-56.525 mm (2.224-2.225 inch) Connecting Rod Bearing Bore Out-of-Round ......................................................................................................... 0.004-0.008 mm (0.00015-0.0003 inch) Connecting Rod Bearing Clearance (Production) .................................................................................................... 0.023-0.065 mm. (0.0009-0.0025 inch) Connecting Rod Bearing Clearance (Service Limit) ................................................................................................... 0.023-0.076 mm (0.0009-0.003 inch) Connecting Rod Side Clearance ........................................................................................................................................ 0.11-0.51 mm (0.0043-0.02 inch) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Engine - Revised Connecting Rod Bolt Torque Connecting Rod: Technical Service Bulletins Engine - Revised Connecting Rod Bolt Torque Bulletin No.: 07-06-01-002 Date: March 05, 2007 INFORMATION Subject: Information on Revised Connecting Rod Bolt Torque for Small Block GEN III and GEN IV Vortec(TM) V8 Engines Models A new connecting rod bolt torque specification was introduced to the GEN III and GEN IV Vortec(TM) small block V8 engines. The connecting rod bolts should continue to be tightened using two passes. The second pass value has been increased from 75 degrees to 85 degrees. Install the connecting rod bolts and tighten. Refer to Piston, Connecting Rod, and Bearing Installation in SI. Tighten Tighten the connecting rod bolts a first pass to 20 N.m (15 lb ft). Tighten the connecting rod bolts a final pass to 85 degrees using the J 45059 Angle Meter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Engine - Revised Connecting Rod Bolt Torque > Page 3413 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Page 3414 Connecting Rod: Specifications Connecting Rod Connecting Rod Bearing Bore Diameter ................................................................................................................... 56.505-56.525 mm (2.224-2.225 inch) Connecting Rod Bearing Bore Out-of-Round ......................................................................................................... 0.004-0.008 mm (0.00015-0.0003 inch) Connecting Rod Bearing Clearance (Production) .................................................................................................... 0.023-0.065 mm. (0.0009-0.0025 inch) Connecting Rod Bearing Clearance (Service Limit) ................................................................................................... 0.023-0.076 mm (0.0009-0.003 inch) Connecting Rod Side Clearance ........................................................................................................................................ 0.11-0.51 mm (0.0043-0.02 inch) Connecting Rod Bolts-Early Design (First Pass) ...................................................................................................................................... 20 Nm (15 ft. lbs.) Connecting Rod Bolts-Early Design (Final Pass) ................................................................................................................................................. 85 degrees Connecting Rod Bolts-Later Design (First Pass) ...................................................................................................................................... 20 Nm (15 ft. lbs.) Connecting Rod Bolts-Later Design (Final Pass) .................................................................................................................................................. 85 degrees Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Engine Block Coolant Drain Plugs ........................................................................................................................................................... 60 Nm (44 ft. lbs.) Cylinder Head Coolant Plug ................................................................................... .................................................................................. 20 Nm (15 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Engine Mechanical Specifications - (Unit Repair) Crankshaft Main Bearing: Specifications Engine Mechanical Specifications - (Unit Repair) Crankshaft Bearing Clearance (Production) ................................................................................................................................ 0.020-0.052 mm (0.0008-0.0021 inch) Bearing Clearance (Service) ...................................................................................................................................... 0.020-0.065 mm (0.0008-0.0025 inch) Connecting Rod Journal Diameter (Production) ........................................................................................................... 53.318-53.338 mm (2.099-2.1 inch) Connecting Rod Journal Diameter (Service Limit) ................................................................................. 53.308 mm (Minimum) (2.0987 inch (Minimum)) Connecting Rod Journal Taper (Production) ............... 0.005 mm (Maximum for one half of the Journal Length (0.0002 inch (Maximum for one half of the Journal Length)) Connecting Rod Journal Taper (Service Limit) .......................................................................................... 0.02 mm (Maximum) 0.00078 inch (Maximum) Connecting Rod Journal Out-of-Round (Production) ...................................................................................................................... 0.005 mm (0.0002 inch) Connecting Rod Journal Out-of-Round (Service Limit) .................................................................................................................... 0.01 mm (0.0004 inch) End Play .............................................................................................................................................. ............................ 0.04-0.2 mm (0.0015-0.0078 inch) Main Journal Diameter (Production) ....................................................................................................................... 64.993-65.007 mm (2.558-2.5593 inch) Main Journal Diameter (Service Limit) ..................................................................................................... 64.993 mm (Minimum) (2.558 inch (Minimum)) Main Journal Out-of-Round (Production) ........................................................................................................................................ 0.003 mm (0.0001 inch) Main Journal Out-of-Round (Service Limit) ................................................................................................................................... 0.008 mm (0.0003 inch) Main Journal Taper (Production) ....................................................................................................................................................... 0.01 mm (0.0004 inch) Main Journal Taper (Service Limit) ................................................................................................................................................ 0.02 mm (0.00078 inch) Reluctor Ring Runout (Measured 1.0 mm (0.04 inch) Below the Tooth Diameter) ...................................... 0.7 mm (Maximum) (0.028 inch (Maximum)) Runout (at Rear Flange) ............................................................................................................................... 0.05 mm (Maximum) (0.002 inch (Maximum)) Thrust Wall Runout .................................................................... ....................................................................................................... 0.025 mm (0.001 inch) Thrust Wall Width (Production) ................................................................................................................................. 26.14-26.22 mm (1.029-1.0315 inch) Thrust Wall Width (Service) ...................................................................................................................... 26.2 mm (Maximum) (1.0315 inch (Maximum)) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Engine Mechanical Specifications - (Unit Repair) > Page 3422 Crankshaft Main Bearing: Specifications Fastener Tightening Specifications Crankshaft Main Bearing Crankshaft Bearing Cap Bolts (Inner Bolts-First Pass in Sequence) ........................................................................................................ 20 Nm (15 ft. lbs.) Crankshaft Bearing Cap Bolts (Inner Bolts-Final Pass in Sequence) .................................................................................................................... 80 degrees Crankshaft Bearing Cap Bolts (Outer Bolts-First Pass in Sequence) ........................................................................................................ 20 Nm (15 ft. lbs.) Crankshaft Bearing Cap Bolts (Outer Bolts-Final Pass in Sequence) ................................................................................................................... 51 degrees Crankshaft Bearing Cap Side Bolts .......................................................................................................................................................... 25 Nm (18 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Specifications Crankshaft Seal Retainer: Specifications Engine Rear Cover Bolt ....................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Specifications > Page 3426 Crankshaft Seal Retainer: Service and Repair Engine Rear Cover Replacement - Tools Required - J41476 Front and Rear Cover Alignment (at crankshaft seal area) Removal Procedure 1. Remove the engine flywheel. 2. Remove the oil pan-to-rear cover bolts (1). 3. Remove the rear cover bolts. 4. Remove the rear cover and gasket. 5. Discard the rear cover gasket. 6. Clean and inspect the rear cover. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Specifications > Page 3427 Important: Do not reuse the crankshaft oil seal or rear cover gasket. - Do not apply any type of sealant to the rear cover gasket (unless specified). - The special tool in this procedure is used to properly center the crankshaft rear oil seal. - The crankshaft rear oil seal will be installed after the rear cover has been installed and aligned. Install the rear cover without the crankshaft oil seal. All gasket surfaces should be free of oil or other foreign material during assembly. - The crankshaft rear oil seal MUST be centered in relation to the crankshaft. - An improperly aligned rear cover may cause premature rear oil seal wear and/or engine assembly oil leaks. 1. Apply a 5 mm (0.20 inch) bead of sealant GM U.S. P/N 12378190, or equivalent 20 mm (0.80 inch) long to the oil pan to engine block junction. 2. Install the rear cover gasket and cover. 3. Install the rear cover bolts until snug. Do not overtighten. 4. Install the oil pan-to-rear cover bolts (1) until snug. Do not overtighten. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Specifications > Page 3428 5. Rotate the crankshaft until two opposing flywheel bolt holes are parallel to the oil pan surface. Important: The tapered legs of the alignment tool must enter the rear cover oil seal bore. 6. Install the J 41476 and bolts onto the rear of the crankshaft. Notice: Refer to Fastener Notice in Service Precautions. 7. Tighten the J41476 mounting bolts until snug. Do not overtighten. 7.1. Tighten the oil pan-to-rear cover bolts to 12 Nm (106 inch lbs.). 7.2. Tighten the engine rear cover bolts to 25Nm (18lbft). 8. Remove the J41476. 9. Install a NEW crankshaft rear oil seal. 10. Install the engine flywheel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Engine Mechanical Specifications (Unit Repair) Crankshaft: Specifications Engine Mechanical Specifications (Unit Repair) Crankshaft Bearing Clearance (Production) ................................................................................................................................ 0.020-0.052 mm (0.0008-0.0021 inch) Bearing Clearance (Service) ...................................................................................................................................... 0.020-0.065 mm (0.0008-0.0025 inch) Connecting Rod Journal Diameter (Production) ........................................................................................................... 53.318-53.338 mm (2.099-2.1 inch) Connecting Rod Journal Diameter (Service Limit) ................................................................................. 53.308 mm (Minimum) (2.0987 inch (Minimum)) Connecting Rod Journal Taper (Production) ........... 0.005 mm (Maximum for one half of the Journal Length (0.0002 inch (Maximum for one half of the Journal Length)) Connecting Rod Journal Taper (Service Limit) ....................................................................................... 0.02 mm (Maximum) (0.00078 inch (Maximum)) Connecting Rod Journal Out-of-Round (Production) ...................................................................................................................... 0.005 mm (0.0002 inch) Connecting Rod Journal Out-of-Round (Service Limit) .................................................................................................................... 0.01 mm (0.0004 inch) End Play .............................................................................................................................................. ............................ 0.04-0.2 mm (0.0015-0.0078 inch) Main Journal Diameter (Production) ....................................................................................................................... 64.993-65.007 mm (2.558-2.5593 inch) Main Journal Diameter (Service Limit) ..................................................................................................... 64.993 mm (Minimum) (2.558 inch (Minimum)) Main Journal Out-of-Round (Production) ........................................................................................................................................ 0.003 mm (0.0001 inch) Main Journal Out-of-Round (Service Limit) ................................................................................................................................... 0.008 mm (0.0003 inch) Main Journal Taper (Production) ....................................................................................................................................................... 0.01 mm (0.0004 inch) Main Journal Taper (Service Limit) ................................................................................................................................................ 0.02 mm (0.00078 inch) Reluctor Ring Runout (Measured 1.0 mm (0.04 inch) Below the Tooth Diameter) ...................................... 0.7 mm (Maximum) (0.028 inch (Maximum)) Runout (at Rear Flange) ............................................................................................................................... 0.05 mm (Maximum) (0.002 inch (Maximum)) Thrust Wall Runout .................................................................... ....................................................................................................... 0.025 mm (0.001 inch) Thrust Wall Width (Production) ................................................................................................................................. 26.14-26.22 mm (1.029-1.0315 inch) Thrust Wall Width (Service) ...................................................................................................................... 26.2 mm (Maximum) (1.0315 inch (Maximum)) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Engine Mechanical Specifications (Unit Repair) > Page 3433 Crankshaft: Specifications Fastener Tightening Specifications Crankshaft Oil Deflector Nut ................................................................................................................ .................................................... 25 Nm (18 ft. lbs.) Crossbar Bolt .................................................... ...................................................................................................................................... 100 Nm (74 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications Engine Block Heater: Specifications Engine Block Heater ............................................................................................................................ ..................................................... 40 Nm (30 ft. lbs.) Coolant Heater Cord Bolt ................................. ....................................................................................................................................... 8 Nm (71 inch lbs.) Coolant Heater ..................................................................................................................... ..................................................................... 50 Nm (37 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement Engine Block Heater: Service and Repair Coolant Heater Cord Replacement Coolant Heater Cord Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Disconnect the coolant heater electrical connector (2). 3. Remove the coolant heater cord retainer and bolts. 4. Remove the coolant heater cord. Installation Procedure Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement > Page 3439 1. Install the coolant heater cord. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the coolant heater cord bolts and retainer. - Tighten the coolant heater cord bolts to 8 Nm (71 inch lbs.). 3. Connect the coolant heater electrical connector (2). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement > Page 3440 Engine Block Heater: Service and Repair Coolant Heater Replacement Coolant Heater Replacement (4.8L, 5.31-, and 6.0L Engines) Removal Procedure 1. Drain the cooling system/engine block. Refer to Draining and Filling Cooling System. 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 3. Remove the oil pan skid plate bolts and plate. 4. Remove the oil cooler hose bracket bolt (1). 5. Remove the oil cooler hose adapter bolts (2). 6. Remove and discard the oil cooler hose adapter gasket. 7. Position the oil cooler hose adapter end out of the way. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement > Page 3441 8. Disconnect the coolant heater electrical connector (2). Important: Do not score the surface of the engine block hole when removing the coolant heater. 9. Remove the coolant heater from the engine block. 10. Remove any burrs, sealer, or other rough spots. Installation Procedure 1. If reusing the old coolant heater, apply thread sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the coolant heater to the engine block. - Tighten the coolant heater to 50 Nm (37 ft. lbs.). Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement > Page 3442 3. Connect the coolant heater electrical connector (2). 4. Position the oil cooler hose adapter end. 5. Install a NEW oil cooler hose adapter gasket. 6. Install the oil cooler hose adapter bolts (2). - Tighten the oil cooler hose adapter bolts to 12 Nm (106 inch lbs.). 7. Install the oil cooler hose bracket bolt (1). - Tighten the oil cooler hose bracket bolt to 25 Nm (118 ft. lbs.). 8. Install the oil pan skid plate and bolts. - Tighten the oil pan skid plate bolts to 20 Nm (15 ft. lbs.). 9. Lower the vehicle. 10. Fill the cooling system/engine block. Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Valley Cover > Component Information > Specifications Engine Valley Cover: Specifications Engine Valley Cover Bolt ..................................................................................................................... .................................................... 25 Nm (18 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Valley Cover > Component Information > Specifications > Page 3446 Engine Valley Cover: Service and Repair Engine Valley Cover Replacement Removal Procedure 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. 5. Remove the engine valley cover bolts. 6. Remove the engine valley cover and gasket. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Valley Cover > Component Information > Specifications > Page 3447 7. Discard the old gasket. 8. Remove the knock sensor oil seals (1) from the cover (2). 9. Clean and inspect the engine valley cover. Installation Procedure Important: All gasket surfaces should be free of oil or other foreign material during assembly. 1. Lubricate the NEW knock sensor seals (1) with clean engine oil. 2. Install the knock sensor oil seals (1) into the engine valley cover (2). 3. Install the engine valley cover and a NEW gasket onto the engine block. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the engine valley cover bolts. - Tighten the bolts to 25 Nm (18 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Valley Cover > Component Information > Specifications > Page 3448 5. Install the knock sensors. - Tighten the sensors to 20 Nm (15 ft. lbs.). 6. Connect the knock sensor electrical connectors. 7. Push down on the rubber covers. 8. Install the intake manifold. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Balancer Bolt Installation Pass-to Ensure the Balancer is Completely Installed ......................................................................................................... 330 Nm (240 ft. lbs.) First Pass Install a NEW Bolt After the Installation Pass and Tighten as Described in the First and Final Passes ................................... 50 Nm (37 ft. lbs.) Final Pass ............................................................. ............................................................................................................................................... 140 degrees Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3452 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement - Tools Required J 41816 Crankshaft Balancer Remover - J 41816-2 Crankshaft End Protector - J 42386-A Flywheel Holding Tool - J 41665 Crankshaft Balancer and Sprocket Installer - J 36660-A Torque Angle Meter Removal Procedure 1. Remove the air conditioning (A/C) drive belt, if equipped. 2. Remove the accessory drive belt, if not equipped with A/C. 3. Remove the fan shroud - lower. 4. Remove the starter motor. Important: Make sure that the teeth of the J 42386-A mesh with the teeth of the engine flywheel. - The crankshaft balancer is balanced as an individual component. It is not necessary to mark the balancer prior to removal. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the J 42386-A and bolts. Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation. Tighten the J 42386-A bolts to 50 Nm (37 ft. lbs.). 6. Remove the crankshaft balancer bolt. Do not discard the crankshaft balancer bolt. The balancer bolt will be used during the balancer installation procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3453 7. Use the J 41816 and J 41816-2 in order to remove the crankshaft balancer. 8. Remove the J41816 and the J41816-2 from the crankshaft balancer. 9. Clean and inspect the crankshaft balancer. Installation Procedure Important: Make sure that the teeth of J 42386-A mesh with the teeth of the engine flywheel. - The used crankshaft balancer bolt will be used only during the first pass of the balancer installation procedure. Install a NEW bolt and tighten as described in the second, third and forth passes of the balancer bolt tightening procedure. - The crankshaft balancer installation and bolt tightening involves a four stage tightening process. The first pass ensures that the balancer is installed completely onto the crankshaft. The second, third, and forth passes tighten the new bolt to the proper torque. Important: The balancer should be positioned onto the end of the crankshaft as straight as possible prior to tool installation. 1. Install the crankshaft balancer onto the end of the crankshaft. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3454 2. Use the J 41665 in order to install the crankshaft balancer. 2.1. Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into the front of the balancer. 2.2. Use a wrench and hold the hex end of the threaded rod. 2.3. Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto the crankshaft. 2.4. Remove the tool and reverse the installation tool. Position the larger end of the installer against the front of the balancer. 2.5. Use a wrench and hold the hex end of the threaded rod. 2.6. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft. - Remove the balancer installation tool. 3. Install the used crankshaft balancer bolt. - Tighten the USED crankshaft balancer bolt to 330 Nm (240 ft. lbs.). 4. Remove the used crankshaft balancer bolt. Important: The nose of the crankshaft should be recessed 2.4 - 4.48 mm (0.094 - 0.176 inch) into the balancer bore. 5. Measure for a correctly installed balancer. If the balancer is not installed to the proper dimensions, install the J 41665 and repeat the installation procedure. 6. Install a NEW crankshaft balancer bolt. 6.1. Tighten the crankshaft balancer bolt a first pass to 50 Nm (37 ft. lbs.). 6.2. Tighten the crankshaft balancer bolt a second pass to 140 degrees using J 36660-A. 7. Remove the J 42386-A and bolts. 8. Install the starter motor. 9. Install the fan shroud - lower. 10. Install the accessory drive belt (if not equipped with A/C). 11. Install the A/C drive belt (if equipped). 12. Perform the crankshaft position (CKP) system variation learn procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Outside Diameter (at Size Point) ............................................................................................................................... 95.962-95.980 mm (3.778-3.779 inch) Piston to Bore Clearance (Production) ...................................................................................................................... 0.020-0.061 mm (0.0008-0.0024 inch) Piston to Bore Clearance (Service Limit) ....................................................................... 0.0.020-0.086 mm (Maximum) (0.0008-0.0034 inch (Maximum)) Piston Pin Clearance to Piston Bore (Production) .................................................................................................................. 0.007-0.020 mm (0.00027-0.00078 inch) Pin Clearance to Piston Bore (Service Limit) ............................................................... 0.007-0.021 mm (Maximum) (0.00027-0.00082 inch (Maximum)) Diameter .......................................................................................................................... .......................................... 23.997-24.0 mm (0.9447-0.9448 inch) Fit in Connecting Rod .............................................................................................. 0.020-0 043 mm (Interference) (0.00078-0.00169 inch (Interference)) Piston Rings Compression Ring End Gap (Production-Top) (Measured in Cylinder Bore) .................................................................. 0.23-0.44 mm (0.009-0.017 inch) Compression Ring End Gap (Production-2nd) (Measured in Cylinder Bore) ............................................................... 0.44-0.70 mm (0.0173-0.0275 inch) Oil Ring End Gap (Production) (Measured in Cylinder Bore) ........................................................................................ 0.18-0.75 mm (0.007-0.0295 inch) Compression Ring End Gap (Service-Top) (Measured in Cylinder Bore) .................................. 0.23-0.50 mm (Maximum) (0.009-0.02 inch (Maximum)) Compression Ring End Gap (Service-2nd)(Measured in Cylinder Bore) ................................. 0.44-0.76 mm (Maximum) (0.0173-0.03 inch (Maximum)) Oil Ring End Gap-Service Limit (Measured in Cylinder Bore) ................................................ 0.18-0.81 mm (Maximum) (0.007-0.032 inch (Maximum)) Compression Ring Groove Clearance (Production-Top) ...................................................................................... 0.04-0.085 mm (0.00157-0.003346 inch) Compression Ring Groove Clearance (Production-2nd) ........................................................................................... 0.04-0.078 mm (0.00157-0.0031 inch) Oil Ring Groove Clearance (Production) .................................................................................................................... 0.012-0.20 mm (0.0005-0.0078 inch) Compression Ring Groove Clearance (Service-Top) .................................................... 0.04-0.085 mm (Maximum) (0.00157-0.003346 inch (Maximum)) Compression Ring Groove Clearance (Service-2nd) ........................................................... 0.0-0.078 mm (Maximum) (0.00157-0.0031 inch (Maximum)) Oil Ring Groove Clearance (Service Limit) ........................................................................ 0.012-0.20 mm (Maximum) (0.0005-0.0078 inch (Maximum)) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston Pin Piston Pin Clearance to Piston Bore (Production) ................................................................................................. 0.007-0.020 mm (0.00027-0.00078 inch) Piston Pin Clearance to Piston Bore (Service Limit) ..................................................... 0.007-0.021 mm (Maximum) (0.00027-0.00082 inch (Maximum)) Piston Pin Diameter ................................................................................................................................................... 23.997-24.0 mm (0.9447-0.9448 inch) Piston Pin Fit in Connecting Rod ............................................................................ 0.020-0 043 mm (Interference) (0.00078-0.00169 inch (Interference)) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Rings Compression Ring End Gap (Production-Top) (Measured in Cylinder Bore) ..................................................................... 0.23-0.44 mm 0.009-0.017 inch Compression Ring End Gap (Production-2nd) (Measured in Cylinder Bore) ................................................................. 0.44-0.70 mm 0.0173-0.0275 inch Oil Ring End Gap (Production) (Measured in Cylinder Bore) .......................................................................................... 0.18-0.75 mm 0.007-0.0295 inch Compression Ring End Gap (Service-Top) (Measured in Cylinder Bore) .................................. 0.23-0.50 mm (Maximum) 0.009-0.02 inch (Maximum) Compression Ring End Gap (Production-Top) (Measured in Cylinder Bore) .................................................................. 0.23-0.44 mm (0.009-0.017 inch) Compression Ring End Gap (Production-2nd) (Measured in Cylinder Bore) ............................................................... 0.44-0.70 mm (0.0173-0.0275 inch) Oil Ring End Gap (Production) (Measured in Cylinder Bore) ........................................................................................ 0.18-0.75 mm (0.007-0.0295 inch) Compression Ring End Gap (Service-Top) (Measured in Cylinder Bore) .................................. 0.23-0.50 mm (Maximum) (0.009-0.02 inch (Maximum)) Compression Ring End Gap (Service-2nd)(Measured in Cylinder Bore) ................................. 0.44-0.76 mm (Maximum) (0.0173-0.03 inch (Maximum)) Oil Ring End Gap-Service Limit (Measured in Cylinder Bore) ................................................ 0.18-0.81 mm (Maximum) (0.007-0.032 inch (Maximum)) Compression Ring Groove Clearance (Production-Top) ...................................................................................... 0.04-0.085 mm (0.00157-0.003346 inch) Compression Ring Groove Clearance (Production-2nd) ........................................................................................... 0.04-0.078 mm (0.00157-0.0031 inch) Oil Ring Groove Clearance (Production) .................................................................................................................... 0.012-0.20 mm (0.0005-0.0078 inch) Compression Ring Groove Clearance (Service-Top) .................................................... 0.04-0.085 mm (Maximum) (0.00157-0.003346 inch (Maximum)) Compression Ring Groove Clearance (Service-2nd) ........................................................... 0.0-0.078 mm (Maximum) (0.00157-0.0031 inch (Maximum)) Oil Ring Groove Clearance (Service Limit) ........................................................................ 0.012-0.20 mm (Maximum) (0.0005-0.0078 inch (Maximum)) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE CAUTION: ^ Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. ^ Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 1. Install the fuel pressure gauge to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gauge in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gauge. 7. Inspect for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3472 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance Of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 2. Remove the engine sight shield. 3. Loosen the fuel filler cap in order to relieve the fuel tank vapor pressure. 4. Connect the J 34730-1A to the fuel pressure valve. 5. Install the bleed hose of the gauge into an approved container. 6. Open the valve on the gauge to bleed the system pressure. The fuel connections are now safe for servicing. 7. Drain any fuel remaining in the gauge into an approved container. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 02-06-01-029 > Sep > 02 > Engine - Needle Bearings Found Upon Oil Change Rocker Arm Assembly: Customer Interest Engine - Needle Bearings Found Upon Oil Change File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-029 Date: September, 2002 INFORMATION Subject: Needle Bearings Found in Oil Pan (Replace Rocker Arms) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird 2002 Cadillac Escalade, Escalade EXT 1999-2002 Chevrolet Silverado 2000-2002 Chevrolet Suburban, Tahoe 2002 Chevrolet Avalanche 1999-2002 GMC Sierra 2000-2002 GMC Yukon, Yukon XL 2003 HUMMER H2 with 4.8L, 5.3L, 5.7L or 6.0L V8 Engine (VINs V, T, G, S, U - RPOs LR4, LM7, LS1, L56, L04, L09) Condition Some customers may comment or technicians may notice needle bearings being found during an engine oil change. The bearings may be found in either the drain pan used or on the magnetic oil pan drain plug. Cause One or more rocker arms may have experienced a bearing failure. Correction 1. Inspect all of the rocker arms for bearing retainer cap failure. If one or more defective rocker arms are found, replace all 16 rocker arms. Refer to the Engine Mechanical sub-section in the appropriate Service Manual. 2. If no condition with the rocker arms is found, refer to the service history for previous rocker arm repair. If previous rocker arm repair was made, then the engine may not have been thoroughly cleaned of loose roller bearings. If no previous rocker arm repair was made, then look for another condition. 3. Remove the oil pan and clean out any additional bearings found within the oil pan. Refer to the Engine Mechanical sub-section in the appropriate Service Manual. 4. Install the oil pan. Refer to the Engine Mechanical sub-section in the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 02-06-01-029 > Sep > 02 > Engine - Needle Bearings Found Upon Oil Change > Page 3481 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 02-06-01-029 > Sep > 02 > Engine - Needle Bearings Found Upon Oil Change Rocker Arm Assembly: All Technical Service Bulletins Engine - Needle Bearings Found Upon Oil Change File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-029 Date: September, 2002 INFORMATION Subject: Needle Bearings Found in Oil Pan (Replace Rocker Arms) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird 2002 Cadillac Escalade, Escalade EXT 1999-2002 Chevrolet Silverado 2000-2002 Chevrolet Suburban, Tahoe 2002 Chevrolet Avalanche 1999-2002 GMC Sierra 2000-2002 GMC Yukon, Yukon XL 2003 HUMMER H2 with 4.8L, 5.3L, 5.7L or 6.0L V8 Engine (VINs V, T, G, S, U - RPOs LR4, LM7, LS1, L56, L04, L09) Condition Some customers may comment or technicians may notice needle bearings being found during an engine oil change. The bearings may be found in either the drain pan used or on the magnetic oil pan drain plug. Cause One or more rocker arms may have experienced a bearing failure. Correction 1. Inspect all of the rocker arms for bearing retainer cap failure. If one or more defective rocker arms are found, replace all 16 rocker arms. Refer to the Engine Mechanical sub-section in the appropriate Service Manual. 2. If no condition with the rocker arms is found, refer to the service history for previous rocker arm repair. If previous rocker arm repair was made, then the engine may not have been thoroughly cleaned of loose roller bearings. If no previous rocker arm repair was made, then look for another condition. 3. Remove the oil pan and clean out any additional bearings found within the oil pan. Refer to the Engine Mechanical sub-section in the appropriate Service Manual. 4. Install the oil pan. Refer to the Engine Mechanical sub-section in the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 02-06-01-029 > Sep > 02 > Engine - Needle Bearings Found Upon Oil Change > Page 3487 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 3488 Rocker Arm Assembly: Specifications Valve Rocker Arm Bolt ........................................................................................................................ .................................................... 30 Nm (22 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 3489 Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the valve rocker arm cover. Important: Place the valve rocker arms, pushrods, and pivot support, in a rack so that the can be installed in the same location from which they were removed. 2. Remove the valve rocker arm bolts. 3. Remove the valve rocker arms. 4. Remove the valve rocker arm pivot support. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 3490 5. Remove the pushrods. 6. Clean and inspect the valve rocker arms and pushrods. Installation Procedure Important: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. 1. Lubricate the valve rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the valve rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the valve rocker arm. 3. Install the valve rocker arm pivot support. Important: Make sure that the pushrods seat properly to the valve lifter sockets. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 3491 4. Install the pushrods. Important: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. 5. Install the rocker arms and bolts. 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The engine firing order is 1,8,7,2,6,5,4,3. Cylinders 1,3,5 and 7 are the left bank. Cylinder 2,4,6 and 8 are the right bank. Notice: Refer to Fastener Notice in Service Precautions. 7. With the engine in the number one firing position, tighten the following valve rocker arm bolts: - Tighten the cylinders 1,2,7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). - Tighten the cylinders 1,3,4 and 5 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following valve rocker arm bolts: - Tighten the cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). - Tighten the cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 10. Install the valve rocker arm cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Valve Rocker Cover Bolt ..................................................................................................................... ............................................... 12 Nm (106 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement (Left) Valve Rocker Arm Cover Replacement - Left Removal Procedure 1. Remove the engine sight shield, if required. 2. Remove the connector position assurance (CPA) lock. 3. Disconnect the main electrical connector (2) feeding the ignition coils. 4. Remove the harness clips (1). 5. Reposition the engine harness, if necessary. 6. Remove the spark plug wires from the ignition coils. - Twist each plug wire 1/2 turn. - Pull only on the boot in order to remove the wire from the ignition coil. 7. Remove the ignition coil bracket studs from the rocker arm cover. 8. Remove the ignition coils and bracket from the rocker arm cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3497 9. Remove the positive crankcase ventilation (PCV) hose from the rocker arm cover. 10. Remove the valve rocker arm cover bolts. 11. Remove the valve rocker arm cover. 12. Remove the gasket (1) from the rocker cover. 13. Discard the OLD gasket. 14. Clean and inspect the rocker arm cover. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3498 Important: All gasket surfaces should be free of oil an/or other foreign material during assembly. - DO NOT reuse the valve rocker arm cover gasket. - The valve rocker arm cover bolt grommets may be reused. - If the PCV valve grommet has been removed from the rocker cover, install a NEW grommet during assembly. 1. Install a NEW rocker cover gasket (1) into the valve rocker cover lip. 2. Install the valve rocker arm cover onto the cylinder head. 3. Install new rocker arm cover grommets, if necessary. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the rocker arm cover bolts. - Tighten the bolts to 12 Nm (106 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3499 5. Install the PCV hose to the rocker arm cover. 6. Apply threadlock GM U.S. P/N 12345382, Canada P/N 10953489, or equivalent to the threads of the bracket bolts. 7. Install the ignition coils and bracket to the rocker arm cover. 8. Install the ignition coil bracket studs to the rocker arm cover. - Tighten the studs to 12 Nm (106 inch lbs.). 9. Install the spark plug wires to the ignition coils. 10. Position the engine harness, if necessary. 11. Install the harness clips (1). 12. Connect the main electrical connector (2) feeding the ignition coils. 13. Install the CPA lock. 14. Install the engine sight shield, if required. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3500 Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement (Right) Valve Rocker Arm Cover Replacement - Right Removal Procedure 1. Remove the engine sight shield, if required. 2. Remove the connector position assurance (CPA) lock. 3. Disconnect the main electrical connector (1) feeding the ignition coils. 4. Remove the harness clips (2). 5. Reposition the engine harness, if necessary. 6. Remove the spark plug wires from the ignition coils. - Twist each plug wire 1/2 turn. - Pull only on the boot in order to remove the wire from the ignition coil. 7. If equipped with the 4.8L, 5.3L, or 6.0L (LQ4) engine, perform the following: 7.1. Reposition the surge tank/heater hoses from the heater hose bracket. 7.2. Remove the heater hose bracket nut and bracket. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3501 8. Remove the ignition coil bracket studs from the rocker arm cover. 9. Remove the ignition coils and bracket from the rocker cover. 10. Remove the positive crankcase ventilation (PCV) hose from the throttle body and rocker cover. 11. Remove the valve rocker arm cover bolts. 12. Remove the valve rocker arm cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3502 13. Remove the gasket (1) from the rocker cover. 14. Discard the OLD gasket. 15. Remove the oil fill cap from the oil fill tube. 16. Remove the oil fill tube from the rocker cover, if required. 17. Discard the oil fill tube. 18. Clean and inspect the rocker arm cover. Installation Procedure Important: All gasket surfaces should be free of oil or other foreign material during assembly. - DO NOT reuse the valve rocker arm cover gasket. - The valve rocker arm cover bolt grommets may be reused. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3503 - If the oil fill tube has been removed from the rocker arm cover, install a NEW fill tube during assembly. 1. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil. 2. Insert the NEW oil fill tube into the rocker arm cover. Rotate the tube clockwise until locked in the proper position. 3. Install the oil fill cap into the tube. Rotate the cap clockwise until locked in the proper position. 4. Install a NEW rocker cover gasket (1) into the valve rocker cover lip. 5. Install the valve rocker arm cover onto the cylinder head. 6. Install new rocker arm cover grommets, if necessary. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the rocker arm cover bolts and grommets. - Tighten the bolts to 12 Nm (106 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3504 8. Install the PCV hose to the throttle body and rocker cover. 9. Apply threadlock GM P/N 12345382, Canada PIN 10953489, or equivalent to the threads of the bracket bolts. 10. Install the ignition coils and bracket to the rocker arm cover. 11. Install the ignition coil bracket studs to the rocker cover. - Tighten the studs to 12 Nm (106 inch lbs.). 12. If equipped with the 4.8L, 5.3L, or 6.0L (LQ4) engine, perform the following: 12.1. Install the heater hose bracket and nut. Tighten the nut to 9 Nm (80 inch lbs.). 12.2. Position the surge tank/heater hoses to the heater hose bracket. 13. Install the spark plug wires to the ignition coils. 14. Position the engine harness, if necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 3505 15. Install the harness clips (2). 16. Connect the main electrical connector (1) feeding the ignition coils. 17. Install the CPA lock. 18. Install the engine sight shield, if required. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Valve Seat Angle ................................................................................................................................................... .................................................................. 46 degrees Runout ............................................................................................................................................................ 0.05 mm (Maximum) 0.002 inch (Maximum) Width (Exhaust) ............................................................ ......................................................................................................................... 1.78 mm (0.07 inch) Width (Intake) ...................................................................................................................................... .................................................. 1.02 mm (0.04 inch) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve Spring Free Length ......................................................................................................................................... ................................................... 52.9 mm (2.08 inch) Installed Height (Exhaust) .............................. ....................................................................................................................................... 45.75 mm (1.8 inch) Installed Height (Intake) ....................................................................................................... ................................................................. 45.75 mm (1.8 inch) Pressure (Closed) ...................................................................................................................................................... 340 N at 45.75 mm (76 lb. at 1.8 inch) Pressure (Open) ..................................................................................................................................................... 980 N at 33.55 mm (220 lb. at 1.32 inch) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 3512 Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement - Tools Required - J 22794 Spark Plug Port Adapter - J 38606 Valve Spring Compressor - J 42078 Valve Stem Oil Seal Installer Removal Procedure 1. Remove the valve rocker arm. 2. Disconnect the spark plug wire at the spark plug. - Twist each plug wire boot 1/2 turn. - Pull only on the boot in order to remove the wire from the spark plug. Important: Remove the spark plugs from the cylinder head with the engine at room temperature. 3. Loosen the spark plug 1 or 2 turns. 4. Brush or air blast away any dirt or debris from around the spark plug. 5. Remove the spark plug. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 3513 6. Install J 22794 into the spark plug hole. 7. Attach an air hose to J22794. 8. Apply compressed air to J 22794 in order to hold the valves in place. 9. Use J 38606 in order to compress the valve spring. 10. Remove the valve stem keys (3). 11. Carefully release the valve spring tension. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 3514 12. Remove the J 38606. 13. Remove the valve spring cap (4). 14. Remove the valve spring (5). Important: A second design valve stem oil seal and shim may be used on later engines. A separate spring shim is not required with the second design seal and shim. 15. Remove the valve stem oil seal (6) (first design). 16. Remove the valve spring shim (7) (first design). 17. Remove the valve stem oil seal and shim (2) (second design) Installation Procedure 1. Clean the cylinder head valve spring seat and/or shim area. 2. Install the valve spring shim (7) (first design). 3. Install the valve stem oil seal and shim (2) (second design). J42078 is not required for installation of the second design seal and shim. Important: The valve stem oil seal alignment and position on the valve guide is critical. An improperly installed valve stem oil seal may lead to excessive oil consumption, increased vehicle emissions, or component damage. 4. Install the valve stem oil seal (first design) onto the guide. 4.1. Lubricate the valve guide and valve stem oil seal with clean engine oil. 4.2. Install the valve stem oil seal (first design) onto the valve stem. Push the seal down until the seal contacts the valve guide. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 3515 4.3. Use the J 42078 in order to install the valve stem oil seal. Push or lightly tap the tool until the tool bottoms against the valve spring shim. 5. Measure the valve stem oil seals (first design) for the properly installed height. There should be a 18.1 - 19.1 mm (0.712 - 0.752 inch) gap between the top edge of the oil seal body and the valve spring shim surface. 6. Install the valve spring (5). 7. Install the valve spring cap (4). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 3516 8. Compress the valve spring using the J 38606. 9. Install the valve keys. - Use grease in order to hold the valve keys in place. - Make sure the keys seat properly in the groove of the valve stem. - Carefully release the valve spring pressure, making sure the valve keys stay in place. - Remove the J 38606. - Tap the end of the valve stem with a plastic faced hammer to seat the keys (if necessary). 10. Remove J 22794 from the spark plug port. Notice: Refer to Fastener Notice in Service Precautions. 11. Hand start the spark plug. - Tighten the spark plug to 15 Nm (11 ft. lbs.). 12. Install the spark plug wires at the ignition coil. 13. Install the spark plug wire to the spark plug. 14. Inspect the wires for proper installation: - Push sideways on each boot in order to check for proper installation. - Reinstall any loose boot. 15. Install the valve rocker arm. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valve System Valve Face Angle ................................................................................................................................ .................................................................. 45 degrees Valve Guide Installed Height (Aluminum Head-Measured from the Cylinder Head Spring Seat Surface to the Top of the Valve Guide) ........... 17.32 mm (0.682 inch) Valve Lash ........................................................................................................................................... ........................................... Net Lash-No Adjustment Valve Lift (Exhaust) ......................................... ................................................................................................................................. 11.85 mm (0.466 inch) Valve Lift (Intake) ........................................................................................................................ ....................................................... 11.6 mm (0.457 inch) Valve Lifter ................................................ ................................................................................................................................................. Hydraulic Roller Valve Margin ............................................................................................................. ............................................................................ 1.25 mm (0.05 inch) Rocker Arm Ratio .................. .............................................................................................................................................................. ........................ 1.70:1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 01-02-32-007 > Sep > 01 > Accessory Drive Belt - Whining Type Noise Drive Belt: Customer Interest Accessory Drive Belt - Whining Type Noise File In Section: 02 - Steering Bulletin No.: 01-02-32-007 Date: September, 2001 TECHNICAL Subject: Accessory Drive Belt Whine (Reposition Power Steering Pump Pulley) Models: 2001-02 Chevrolet and GMC C/K 1500 Series Utility Models (Tahoe, Suburban, Yukon, Yukon XL, Denali, Denali XL) Built at Janesville Assembly Plant (Plant Code J) from December, 2000 through July, 2001 Condition Some customers may comment on a whining-type noise that is audible in the vehicle's passenger compartment. This noise can typically be heard when the vehicle is idling and may vary in pitch as engine RPM is increased. Cause The power steering (PS) pump pulley may be positioned too far inboard on the PS pump. Correction Inspect the PS pump pulley for proper positioning on the PS pump shaft. If it is determined that the pulley is not even/flush with the end of the shaft (+/- 0.25 mm (0.010 in) following the applicable Service Manual procedure and using J 25034-C, reposition the PS pump pulley. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics Drive Belt: All Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 3534 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 3535 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 04-06-01-013 > Apr > 04 > Engine - Serpentine Drive Belt Wear Information Drive Belt: All Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 01-02-32-007 > Sep > 01 > Accessory Drive Belt - Whining Type Noise Drive Belt: All Technical Service Bulletins Accessory Drive Belt - Whining Type Noise File In Section: 02 - Steering Bulletin No.: 01-02-32-007 Date: September, 2001 TECHNICAL Subject: Accessory Drive Belt Whine (Reposition Power Steering Pump Pulley) Models: 2001-02 Chevrolet and GMC C/K 1500 Series Utility Models (Tahoe, Suburban, Yukon, Yukon XL, Denali, Denali XL) Built at Janesville Assembly Plant (Plant Code J) from December, 2000 through July, 2001 Condition Some customers may comment on a whining-type noise that is audible in the vehicle's passenger compartment. This noise can typically be heard when the vehicle is idling and may vary in pitch as engine RPM is increased. Cause The power steering (PS) pump pulley may be positioned too far inboard on the PS pump. Correction Inspect the PS pump pulley for proper positioning on the PS pump shaft. If it is determined that the pulley is not even/flush with the end of the shaft (+/- 0.25 mm (0.010 in) following the applicable Service Manual procedure and using J 25034-C, reposition the PS pump pulley. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics Drive Belt: All Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 3549 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 3550 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 04-06-01-013 > Apr > 04 > Engine - Serpentine Drive Belt Wear Information Drive Belt: All Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customers concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. It the engine is not making the noise do not proceed any further in this table. 3. The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3557 is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3558 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application. Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off. Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one or more grooves on a pulley(s). 3. The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys. 4. This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3559 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s). Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3560 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt(s) may be the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the fibs of the drive belt(s) will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt(s) does not have a smooth surface for proper operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3561 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customers concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. It the engine is not making the noise do not Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3562 proceed any further in this table. 3. The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application. Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off. Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one or more grooves on a pulley(s). 3. The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys. 4. This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3563 Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s). Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s). Drive Belt Rumbling Drive Belt Rumbling Diagnosis Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3564 Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt(s) may be the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the fibs of the drive belt(s) will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt(s) does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3565 Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body, or suspension component, or other item(s) on the vehicle may cause the squeal noise. If the squeal is intermittent, verify that it is not the accessory drive component(s) by varying their load(s), making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. The squeal may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further in this table. 3. The squeal may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the squealing noise is related to the drive belt(s) or an accessory drive component. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. This test is to verify that an accessory drive component(s) does not have a seized bearing. With the belt(s) removed, test the bearings in the accessory drive component(s) for smooth operation. Also test the accessory drive component(s) with the engine operating by varying the load on the accessory drive component(s) to verify that the component(s) is operating properly. 5. This test is to verify that the drive belt(s) tensioner(s) are not operating properly. If the drive belt tensioner(s) are not operating properly, proper belt tension may not be achieved to keep the drive belt(s) from slipping which could cause a squealing noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner(s) from operating properly. Also if the incorrect length drive belt(s) was installed, it may not be routed correctly and may be turning an accessory drive component in the incorrect direction. 7. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 8. Inspect the accessory drive pulley(s) to verify that they are the correct diameter or width. Using a known good vehicle, compare the accessory drive pulleys. Drive Belt Vibration Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3566 Drive Belt Vibration Diagnosis Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components may have an affect on engine vibration. An overcharged air conditioning (A/C) system, a power steering system restriction, or the incorrect fluid, or an extra load placed on the generator are suggested items to inspect. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the vibration is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the vibration is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the drive belt(s). 6. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smooth operation. Inspect for a bent fan shaft or bent mounting flange. 9. Inspect the water pump drive shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known, good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put an extra strain on that accessory drive component causing it to vibrate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3567 Drive Belt Whine Drive Belt Whine Diagnosis Drive Belt Whine Diagnosis Diagnostic Aids The drive belt(s) will not cause the whine. If the whine is intermittent, verify that it is not the accessory drive component(s) by varying their loads, making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description The number(s) below refer to the step(s) in the diagnostic table. 3. This test is to verify that the whine is being caused by the accessory drive component(s). Remove the drive belt(s) and operate the engine for a few seconds this will verify if the whining noise is related to the accessory drive component. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. This inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper removal and installation procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Accessory Drive Belt Replacement Drive Belt: Service and Repair Accessory Drive Belt Replacement Drive Belt Replacement - Accessory Removal Procedure 1. Loosen the air cleaner outlet duct clamps at the following locations: - Throttle body - Mass airflow/intake air temperature (MAF/IAT) sensor 2. Remove the radiator inlet hose clip from the outlet duct. 3. Remove the air cleaner outlet duct. 4. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 5. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt. 6. Remove the belt from the pulleys and the drive belt tensioner. 7. Slowly release the tension on the drive belt tensioner. 8. Remove the breaker bar and socket and from the drive belt tensioner bolt. 9. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Accessory Drive Belt Replacement > Page 3570 1. Route the drive belt around all the pulleys except the idler pulley. 2. Install the breaker bar with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner. 4. Install the drive belt under the idler pulley. 5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner bolt. 7. Inspect the drive belt for proper installation and alignment. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. 8. Install the air cleaner outlet duct. 9. Install the radiator inlet hose clip to the outlet duct. Notice: Refer to Fastener Notice in Service Precautions. 10. Tighten the air cleaner outlet duct clamps at the following locations: - Throttle body - MAF/IAT sensor - Tighten the air cleaner outlet duct clamp screws to 7 Nm (62 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Accessory Drive Belt Replacement > Page 3571 Drive Belt: Service and Repair A/C Belt Drive Belt Replacement - Air Conditioning Removal Procedure 1. Remove the accessory drive belt. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the engine shield bolts. 4. Remove the engine shield. 5. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening. 6. Rotate the A/C belt tensioner clockwise in order to relieve tension on the belt. 7. Remove the A/C belt from the pulleys. 8. Slowly release the tension on the A/C belt tensioner. 9. Remove the ratchet from the A/C belt tensioner. 10. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Accessory Drive Belt Replacement > Page 3572 1. Install the A/C belt around the crankshaft balancer. 2. Install a ratchet into the A/C drive belt tensioner adapter opening 3. Rotate the A/C belt tensioner clockwise in order to relieve tension on the tensioner. 4. Install the A/C belt over the idler pulley. 5. Install the A/C belt around the A/C compressor pulley. 6. Slowly release the tension on the A/C belt tensioner. 7. Remove the ratchet from the A/C belt tensioner. 8. Inspect the A/C belt for proper installation and alignment. 9. Install the engine shield. Notice: Refer to Fastener Notice in Service Precautions. 10. Install the engine shield bolts. - Tighten the engine shield bolts to 20 Nm (15 ft. lbs.). 11. Lower the vehicle. 12. Install the accessory drive belt. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Accessory Drive Belt Tensioner Bolt .................................................................................................................................................... 50 Nm (37 ft. lbs.) Air Conditioning (A/C) Belt Tensioner Bolt ............................................................................................................................................ 50 Nm (37 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 3576 Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis Inspection Procedure Notice: Allowing the drive belt tensioner to snap into the free position may result in damage to the tensioner. Important: When the engine is operating the drive belt tensioner arm will move. Do not replace the drive belt tensioner because of movement in the drive belt tensioner arm. 1. Remove the drive belt. 2. Move the drive belt tensioner through its full travel. - The movement should feel smooth. - There should be no binding. - The tensioner should return freely. 3. If any binding is observed, replace the drive belt tensioner. 4. Install the drive belt. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Drive Belt Tensioner Replacement (Accessory) Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement (Accessory) Drive Belt Tensioner Replacement - Accessory Removal Procedure 1. Remove the accessory drive belt. 2. Remove the drive belt tensioner bolts. 3. Remove the drive belt tensioner. Installation Procedure 1. Install the drive belt tensioner. 2. Install the drive belt tensioner bolts. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the drive belt tensioner bolts. - Tighten the accessory drive belt tensioner bolts to 50 Nm (37 ft. lbs.). 4. Install the accessory drive belt. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Drive Belt Tensioner Replacement (Accessory) > Page 3579 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement (Air Conditioning) Drive Belt Tensioner Replacement - Air Conditioning Removal Procedure 1. Remove the air conditioning (A/C) drive belt. 2. Remove the A/C belt tensioner bolts. 3. Remove the A/C belt tensioner. Installation Procedure 1. Install the A/C belt tensioner. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the A/C belt tensioner bolts. - Tighten the A/C belt tensioner bolts to 50 Nm (37 ft. lbs.). 3. Install the A/C drive belt. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Specifications Engine Accessory Bracket: Specifications Engine Service Lift Bracket M10 Bolt .............................................................................................................................................. ................................................ 50 Nm (37 ft. lbs.) M8 Bolt .................................................................. ........................................................................................................................... 25 Nm (18 ft. lbs.) Engine Shield Bolt ............................................................................................................................... ................................................. 20 Nm (15 ft. lbs.) Engine Wiring Harness Bracket Nut ................................................................................................................................................... 5 Nm (44 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left Engine Accessory Bracket: Service and Repair Engine Mount Bracket Replacement - Left Engine Mount Bracket Replacement- Left Removal Procedure 1. Remove the engine mount. 2. Remove the engine mount bracket bolts. 3. Remove the engine mount bracket. Installation Procedure 1. Install the engine mount bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount bracket bolts. - Tighten the engine mount bracket bolts to 75 Nm (55 ft. lbs.). 3. Install the engine mount. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 3585 Engine Accessory Bracket: Service and Repair Engine Mount Bracket Replacement- Right Engine Mount Bracket Replacement- Right Removal Procedure 1. Remove the engine mount. 2. Remove the engine mount bracket bolts. 3. Remove the engine mount bracket. Installation Procedure 1. Install the engine mount bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount bracket bolts. - Tighten the engine mount bracket bolts to 75 Nm (55 ft. lbs.). 3. Install the engine mount. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications Engine Mount Bolt ............................................................................................................................... .................................................... 50 Nm (37 ft. lbs.) Engine Mount Bracket Bolt ............................... ....................................................................................................................................... 75 Nm (55 ft. lbs.) Engine Mount-to-Engine Mount Bracket Bolt .......................................................................................................................................... 50 Nm (37 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection Engine Mount: Service and Repair Engine Mount Inspection Engine Mount Inspection Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. Notice: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump screen. This will result in a damaged oil pickup unit. 1. Measure the engine movement at the engine mount in order to check for damage to the rubber portions of the mount. 1.1. Apply the park brake. 1.2. Start the engine. 1.3. Firmly apply and hold the primary brakes. 1.4. Have an assistant stand to the side of the vehicle in order to observe for engine movement. 1.5. Slightly load the engine shifting from drive to reverse a few times. 1.6. If the engine moves more than 24 mm (0.945 inch)from the at rest position, in either direction, check for loose engine mount bolts. 2. If the engine mount bolt torque is within specifications, check the condition of the engine mount. 3. Replace the engine mount if any of the following conditions exist: - Heat check cracks cover the rubber cushion surface. - The rubber cushion is separated from the metal plate of the mount. - There is a split through the rubber cushion. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3591 Engine Mount: Service and Repair Engine Mount Replacement - Left Engine Mount Replacement- Left Removal Procedure Notice: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump screen. This will result in a damaged oil pickup unit. 1. Remove the engine mount-to-engine mount bracket bolts. (Right side shown, left side similar). 2. If vehicle is a 2 wheel drive (2WD), raise the vehicle to a height to work through the front wheelhouse opening. 3. If vehicle is a 4 wheel drive (4WD), raise the vehicle in order to remove the front tires and wheels. 4. Remove the left front tire and wheel. 5. Remove the wheelhouse inner panel push pin retainers (2). 6. Remove the wheelhouse inner panel (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3592 7. Remove the engine shield bolts. 8. Remove the engine shield. Important: DO NOT raise and/or support the engine by the crankshaft balancer, or oil pan. 9. Raise and suitably support the engine using adjustable (screw type) jack stands. 10. Remove the engine mount bolts. 11. For vehicles with 4WD, remove the front propeller shaft. 12. Remove the left engine mount. Installation Procedure 1. Position the left engine mount to the engine. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3593 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount bolts. - Tighten the engine mount bolts to 50 Nm (37 ft. lbs.). 3. Lower the engine. 4. Remove the adjustable jack stands. 5. Install the front propeller shaft. 6. Position the engine shield to the vehicle. 7. Install the engine shield bolts. - Tighten the engine shield bolts to 20 Nm (15 ft. lbs.). 8. Lower the vehicle. 9. Install the left front tire and wheel. 10. Install the wheelhouse inner panel push pin retainers (2). 11. Install the wheelhouse inner panel (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3594 12. Install the engine mount-to-engine mount bracket bolts. (Right side shown, left side similar). - Tighten the engine mount-to-engine mount bracket bolts to 65 Nm (48 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3595 Engine Mount: Service and Repair Engine Mount Replacement - Right Engine Mount Replacement - Right Removal Procedure 1. Remove the engine mount-to-engine mount bracket bolts. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the engine shield bolts. 4. Remove the engine shield. 5. Remove the air conditioning (A/C) compressor. 6. Remove the starter motor. Important: DO NOT raise and/or support the engine by the crankshaft balancer, or oil pan. 7. Raise and suitably support the engine using adjustable (screw type) jack stands. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3596 8. Remove the engine mount bolts. 9. Remove the right engine mount. Installation Procedure 1. Position the right engine mount to the engine. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount bolts. - Tighten the engine mount bolts to 50 Nm (37 ft. lbs.). 3. Lower the engine. 4. Remove the adjustable jack stands. 5. Install the starter motor. 6. Install the A/C compressor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Inspection > Page 3597 7. Position the engine shield to the vehicle. 8. Install the engine shield bolts. - Tighten the engine shield bolts to 20 Nm (15 ft. lbs.). 9. Lower the vehicle. 10. Install the engine mount-to-engine mount bracket bolts. - Tighten the engine mount-to-engine mount bracket bolts to 65 Nm (48 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Drive Belt Idler Pulley Bolt ................................................................................................................... ................................................... 50 Nm (37 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications > Page 3601 Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement Removal Procedure 1. Loosen the drive belt idler pulley bolt. 2. Remove the accessory drive belt. 3. Remove the drive belt idler pulley and bolt. Installation Procedure 1. Install the drive belt idler pulley and bolt to the generator bracket. Snug the bolt finger tight. 2. Install the drive belt. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the drive belt idler pulley bolt. - Tighten the drive belt idler pulley bolt to 50 Nm (37 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure Minimum - Hot At 1,000 Revolutions Per Minute (RPM) ...................................................................................................................................................... 41 kPa (6 psig) At 2,000 RPM .................................................................................................................. .......................................................................... 124 kPa (18 psig) At 4,000 RPM .............................. .............................................................................................................................................................. 165 kPa (24 psig) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 3606 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing - Tools Required J 21867 Pressure Gauge - J 42907 Oil Pressure Testing Tool 1. With the vehicle on a level surface, run the vehicle for a few minutes, allow adequate drain down time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gauge or light. 4. Listen for a noisy valve train or a knocking noise. 5. Inspect for the following: - Oil diluted by water or glycol anti freeze - Foamy oil 6. Remove the oil filter and install the J 42907. 7. install J21867 or equivalent to the J42907. 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to Engine Mechanical Specifications. 10. If the engine oil pressure is below specifications, inspect the engine for one or more of the following: - Oil pump worn or dirty. - Oil pump-to-engine block bolts loose. - Oil pump screen loose, plugged, or damaged - Oil pump screen O-ring seal missing or damaged - Malfunctioning oil pump pressure regulator valve - Excessive bearing clearance - Cracked, porous, or restricted oil galleries - Oil gallery plugs missing or incorrectly installed. - Broken valve lifters Repair as necessary 11. If the oil pressure reading on the J 21867 or equivalent is within specifications, inspect for the following: - Plugged or incorrect oil filter and/or malfunctioning oil bypass valve - Malfunctioning oil pressure gauge or sensor Repair as necessary Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications Oil Level Indicator Tube Bolt ............................................................................................................... ................................................... 25 Nm (18 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications > Page 3610 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Replacement Removal Procedure 1. Remove the oil level indicator from the tube. 2. Remove the oil level indicator tube bolt. 3. Remove the oil level indicator tube from the engine block. Important: The O-ring seal may be reused if not cut or damaged. 4. Inspect the O-ring seal for cuts or damage. 5. Remove the O-ring seal from the tube (if required). Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications > Page 3611 1. Lubricate the O-ring seal with clean engine oil. 2. Install the O-ring seal onto the oil level indicator tube. 3. Install the oil level indicator tube behind the exhaust manifold. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Install the oil level indicator tube into the block. The tube must be installed with the collar flush to the block. 6. Lower the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the oil level indicator tube bolt - Tighten the oil level indicator tube bolt to 25 Nm (18 ft. lbs.). 8. Install the oil level indicator to the tube. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3616 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3617 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 5.7L (6.0 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 3620 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Grade ............................................................... ......................................................................................................................................... 5W-30 (preferred) Above -18° C (0° F) ........................................................................................................... ........................................................ 10W-30, 5W-30 (preferred) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 3621 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug hole and plug. 8. Remove the oil filter from the engine block. Important: Check the old oil filter to ensure that the filter seal is not left on the engine block. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 3622 1. Lubricate the oil filter seal with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter to the engine block. - Tighten the oil filter to 30 Nm (22 ft. lbs.). 3. install the oil drain plug to the engine block. - Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator in order to check the level. 10. Add oil if necessary: 11. Close the hood. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Mechanical Specifications Oil Filter: Mechanical Specifications Fastener Tightening Specifications Oil Filter ............................................................................................................................................... .................................................... 30 Nm (22 ft. lbs.) Oil Filter Fitting .................................................. ....................................................................................................................................... 55 Nm (40 ft. lbs.) Engine Mechanical Specifications (5.3L Engine) Oil Filter Type ...................................................................................................................................... ......................................................................... PF59 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Mechanical Specifications > Page 3629 Oil Filter: Capacity Specifications Oil Capacity With Filter Change ............................................................................................................................... ......................................... 5.68 Liters (6.0 Quarts) Without Filter Change .......................................... ........................................................................................................................ 4.73 Liters (5.0 Quarts) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Mechanical Specifications > Page 3630 Oil Filter: Fluid Type Specifications Oil Type ............................................................................................................................................... ....................................................................... 5W-30 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 3631 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug hole and plug. 8. Remove the oil filter from the engine block. Important: Check the old oil filter to ensure that the filter seal is not left on the engine block. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 3632 1. Lubricate the oil filter seal with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter to the engine block. - Tighten the oil filter to 30 Nm (22 ft. lbs.). 3. install the oil drain plug to the engine block. - Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator in order to check the level. 10. Add oil if necessary: 11. Close the hood. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Oil Filter Adapter .................................................................................................................................. ................................................... 55 Nm (40 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter Replacement Oil Filter Adapter: Service and Repair Oil Filter Adapter Replacement Oil Filter Adapter Replacement Removal Procedure 1. Drain the engine oil. 2. Remove the oil filter. 3. Remove the oil filter adapter (1). Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter Replacement > Page 3638 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the oil filter adapter (1). - Tighten the oil filter adapter to 55 Nm (40 ft. lbs.). 2. Install the oil filter. 3. Refill the engine oil. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter Replacement > Page 3639 Oil Filter Adapter: Service and Repair Oil Filter Bypass Valve Replacement Oil Filter Bypass Valve Replacement Removal Procedure 1. Drain the engine oil. 2. Remove the oil filter. 3. Remove the oil filter adapter (1). 4. Remove the oil filter bypass valve (2). Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter Replacement > Page 3640 1. Install the oil filter bypass valve (2). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter adapter (1). - Tighten the oil filter adapter to 55 Nm (40 ft. lbs.). 3. Install the oil filter. - Tighten the oil filter to 30 Nm (22 ft. lbs.). 4. Refill the engine oil. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Specifications Oil Level Sensor: Specifications Oil Level Sensor .................................................................................................................................. ................................................ 13 Nm (115 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Specifications > Page 3644 Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Drain the engine oil. 2. Disconnect the oil level sensor electrical connector (6). 3. Remove the oil level sensor from the oil pan. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the oil level sensor to the oil pan. - Tighten the oil level sensor to 13 Nm (115 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Specifications > Page 3645 2. Connect the oil level sensor electrical connector (6). 3. Fill the engine oil. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Service and Repair Oil Line: Service and Repair Engine Oil Cooler Hose/Pipe Replacement (6.0L and 8.1. Engines) Removal Procedure The optional oil cooler is either an integral part of the radiator or a separate unit placed in front of the radiator. The cooler lines and hoses are serviceable. 1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe. 2. Hold one leg of the retaining clip. 3. Using a small pick-type tool or, bent screwdriver, gently pry the other end of the retaining clip from the quick connect fitting. 4. Rotate the retaining clip out of the quick connect fitting. Remove the retaining clip completely. 5. Discard the OLD retaining clip. 6. If equipped with a 6.OL engine, perform the following: 6.1. Open the oil cooler hose clip located on the lower fan shroud. 6.2. Remove the oil cooler hoses from the clip. 6.3. Gently, pull the oil cooler pipe fittings straight out from the radiator quick connect fittings. 6.4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Service and Repair > Page 3652 7. If equipped with a 8.1. engine, perform the following: 7.1. Remove the oil cooler hoses from the clip. 7.2. Gently, pull the oil cooler pipe fittings straight out from the radiator quick connect fittings. 7.3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 8. It equipped, remove the engine shield bolts. 9. Remove the engine shield. 10. If equipped with the a 6.0L engine, perform the following: 10.1. Remove the oil cooler hose bracket bolt (1). 10.2. Remove the oil cooler hose adapter bolts (2). 10.3. Remove the oil cooler hose assembly and gasket. Discard the gasket. 10.4. Inspect the fittings, connectors and cooler hoses for damage or distortion. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Service and Repair > Page 3653 11. If equipped with a 8.1. engine, perform the following: 11.1. Remove the oil cooler hose bracket bolt. 11.2. Disconnect the quick connect fittings (1) at the engine. 11.3. Remove the oil cooler hose assembly. Discard the gasket. 11.4. Inspect the fittings, connectors and cooler hoses for damage or distortion. Installation Procedure Important: A distinct snap should be heard when assembling tube ends of the hose assembly to quick connectors. To ensure tube is fully inserted into the connector, check by giving tube a forceful pull. 1. If equipped with a 8.1. engine, perform the following: 1.1. Remove the oil cooler hose assembly. 1.2. Connect the quick connect fittings (1) at the engine. Notice: Refer to Fastener Notice in Cautions and Notices. 1.3. Install the oil cooler hose bracket bolt. - Tighten the bolt to 50 Nm (37 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Service and Repair > Page 3654 2. If equipped with a 6.0L engine, perform the following: 2.1. Install the oil cooler hose assembly and a new gasket. 2.2. Install the oil cooler hose adapter bolts (2). - Tighten the bolts to 12 Nm (106 inch lbs.). 2.3. Install the oil cooler hose bracket bolt (1). - Tighten the bolt to 25 Nm (18 ft. lbs.). 3. If equipped, install the engine shield. 4. Install the engine shield bolts. - Tighten the bolts to 20 Nm (15 ft. lbs.). 5. Do not install the new retaining clip onto the fitting by pushing on the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Service and Repair > Page 3655 Important: Failure to properly install the retaining clip could cause the cooler line to come loose and cause damage to the engine. 6. Install the NEW retaining clip into the quick connect fitting by using your thumb and forefinger. Insert the new retaining clip into one of the three fitting recesses. Ensure that the retaining clip is engaged in all 3 slots. 7. With one end of the retaining clip engaged in the connector fitting slot, use your thumb in order to rotate the retaining clip around the connector fitting, until the retaining clip snaps into place. 8. Ensure that the 3 retaining clip ears are seen from inside the fitting and that the retaining clip moves freely in the fitting slots. 9. Install a new retaining clip into the remaining quick connect fitting. 10. If equipped with a 6.01L engine, perform the following: 10.1. Install the oil cooler hoses to the hose clip on the fan shroud. 10.2. Snap the oil cooler hose clip shut. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Service and Repair > Page 3656 Important: Ensure the oil cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new cap. Install the cap on to the cooler line prior to cooler line installation. - Do not use the plastic cap in order to install the cooler line into the fitting. 11. If equipped with a 8.1. engine, perform the following: 11.1. Install the oil cooler hoses to the clip. 11.2. Install the oil cooler lines to the radiator. Install the cooler line straight into the quick connect fitting. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 11.3. Pull back sharply on the cooler line in order to ensure that the cooler line is installed in the quick connect fitting. Important: Do not manually depress the retaining clip when installing the plastic cap. 12. Snap the plastic cap onto the quick connect fitting. 13. Ensure that the plastic cap is fully seated against the fitting. 14. Ensure that no gap is present between the cap and the fitting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Service and Repair > Page 3657 15. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. A hidden yellow identification band indicates proper joint seating. 16. Run the engine. Inspect the engine oil cooling system for leaks. 17. Inspect the engine oil level. Add oil if necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Fastener Tightening Specifications Oil Pan: Specifications Fastener Tightening Specifications Oil Pan Drain Plug ............................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Oil Pan Bolt ...................................................... ........................................................................................................................................ 25 Nm (18 ft. lbs.) To Front Cover .................................................................................................................................... ................................................. 25 Nm (18 ft. lbs.) To Rear Cover ..................................................... ............................................................................................................................... 12 Nm (106 in. lbs.) Oil Pan Skid Plate Bolt ........................................................................................................................ ..................................................... 20 Nm (15 ft. lbs.) Oil Pan Cover Bolts .......................................... .................................................................................................................................. 12 Nm (106 inch lbs.) Oil Pan Drain Plug ....................................................................................................................... ............................................................. 25 Nm (18 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Fastener Tightening Specifications > Page 3662 Oil Pan: Specifications Engine Mechanical Specifications (Unit Repair) Oil Pan and Front/Rear Cover Alignment Oil Pan to Rear of Engine Block Alignment (at Transmission Bellhousing Mounting Surface) ........................... 0.0-0.25 mm (Maximum) (0.0-0.01 inch (Maximum)) Front Cover Alignment (at Oil Pan Surface) ............................................................................................................................... 0.0-0.5 mm (0.0-0.02 inch) Rear Cover Alignment (at Oil Pan Surface) ................................................................................................................................ 0.0-0.5 mm (0.0-0.02 inch) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement Oil Pan: Service and Repair Oil Pan Replacement Oil Pan Replacement Removal Procedure 1. If equipped with four wheel drive (4WD), remove the front differential. 2. Remove the starter motor. 3. Remove the engine shield bolts. 4. Remove the engine shield. 5. If equipped, remove the oil pan skid plate bolts. 6. Remove the oil pan skid plate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3665 7. Remove the crossbar bolts. 8. Remove the crossbar. 9. Remove the transmission cover bolt and cover. 10. Drain the engine oil and remove the engine oil filter. 11. Re-install the drain plug and oil filter until snug. 12. If equipped with the 4L60-E automatic transmission, remove the transmission bolt and stud on the right side. 13. Remove the bottom bolt on the left side. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3666 14. If equipped with the 4L80-E automatic transmission, remove the transmission converter cover bolts. 15. Disconnect the oil level sensor electrical connector (6). 16. Remove the battery cable channel bolt. 17. Slide the channel pin out of the oil pan tab. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3667 18. Remove the following from the positive battery cable clip: - Engine wiring harness clip - Positive battery cable clip 19. Remove the engine oil cooler lines from the positive battery cable clip. 20. Remove the positive battery cable clip bolt and clip. 21. Remove the oil pan bolts. 22. Remove the oil pan. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3668 Important: DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the openings as required. 23. Drill (3) out the oil pan gasket retaining rivets (2), if required. 24. Remove the gasket (1) from the pan. 25. Discard the gasket and rivets. 26. Clean and inspect the engine oil pan. Installation Procedure Important: The alignment of the structural oil pan is critical. The rear bolt hole locations of the oil pan provide mounting points for the transmission bellhousing. To ensure the rigidity of the powertrain and correct transmission alignment, it is important that the rear of the block and the rear of the oil pan must NEVER protrude beyond the engine block and transmission bellhousing plane. - Do not reuse the oil pan gasket. - It is not necessary to rivet the NEW gasket to the oil pan. 1. Apply a 5 mm (0.20 inch) bead of sealant GM U.S. P/N 12378190, or equivalent 20 mm (0.80 inch) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrudes into the oil pan surface. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3669 2. Apply a 5 mm (0.20 inch) bead of sealant GM U.S. P/N 12378190, or equivalent 20 mm (0.8 inch) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface. Important: Be sure to align the oil gallery passages in the oil pan and engine block properly with the oil pan gasket. 3. Pre-assemble the oil pan gasket to the pan. - Install the gasket onto the pan. - Install the oil pan bolts to the pan and through the gasket. 4. Install the oil pan, gasket and bolts to the engine block. 5. Tighten the oil pan bolts until snug. Do not overtighten. 6. Install the transmission converter cover bolts until snug, if equipped with the 4L80-E automatic transmission. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3670 7. Install the transmission bolt and stud on the right side until snug, If equipped with the 4L60-E automatic transmission. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the bottom bolt on the left side until snug. 8.1. Tighten the oil pan and oil pan-to-oil pan front cover bolts to 25 Nm (18 ft. lbs.). 8.2. Tighten the oil pan-to-rear cover bolts to 12 Nm (106 inch lbs.). 8.3. Tighten the bellhousing, converter cover. and transmission bolts/stud to 50 Nm (37 ft. lbs.). 9. Install the positive battery cable clip and bolt to the oil pan. - Tighten the positive battery cable clip bolt to 9 Nm (80 inch lbs.). 10. Install the engine oil cooler lines to the positive battery cable clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3671 11. Install the following to the positive battery cable clip: - Engine wiring harness clip - Positive battery cable clip 12. Slide the channel pin in to the oil pan tab. 13. Install the battery cable channel bolt. - Tighten the battery cable channel bolt to 12 Nm (106 inch lbs.). 14. Connect the oil level sensor electrical connector (6). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3672 15. Install the transmission cover and bolt. - Tighten the transmission cover bolt to 12 Nm (106 inch lbs.). 16. Install the crossbar. 17. Install the crossbar bolts. - Tighten the crossbar bolts to 100 Nm (74 ft. lbs.). 18. If equipped, install the oil pan skid plate. 19. Install the oil pan skid plate bolts. - Tighten the oil pan skid plate bolts to 20 Nm (15 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3673 20. Install the engine shield. 21. Install the engine shield bolts. - Tighten the engine shield bolts to 20 Nm (15 ft. lbs.). 22. Install the starter motor. 23. If equipped with 4WD, install the front differential. 24. Install new engine oil and a new oil filter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3674 Oil Pan: Service and Repair Oil Pan Cover Replacement Oil Pan Cover Replacement Removal Procedure 1. Drain the engine oil. 2. Remove the oil pan cover bolts (1), cover (2), and gasket (3). 3. Discard the gasket. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install a new oil pan cover gasket (3), the cover (2) and bolts (1). - Tighten the oil pan cover bolts to 12 Nm (106 inch lbs.). 2. Refill the engine oil. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3679 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3680 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3681 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3682 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3683 Oil Pressure Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3684 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3685 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3686 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3687 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3688 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3689 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3690 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3691 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3692 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3693 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3694 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3695 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3696 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3697 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3698 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3699 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3700 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3701 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3702 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3703 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3704 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3705 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3706 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3707 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3708 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3709 Oil Pressure Gauge: Electrical Diagrams For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Diagrams. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Page 3710 Oil Pressure Gauge: Description and Operation ENGINE OIL PRESSURE GAGE The IPC uses the engine oil sensor signal to determine the engine oil pressure. The oil pressure sensor signal circuit is hard-wired to the IPC. The engine oil pressure sensor signal to the IPC is a variable resistance ranging from 0-90 Ohms. The sensor resistance is used to drive the engine oil pressure gage. A sensor resistance of 1 Ohm will display as 0 kPa (0 psi) and a resistance of 88 Ohms will display as 550 kPa (80 psi). The IPC monitors the oil pressure sensor signal circuit in order to decide when the oil pressure is too low. The Check Engine Oil Pressure indicator will be displayed in the message center if the IPC detects a low engine oil pressure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Page 3711 Oil Pressure Gauge: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Testing and Inspection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Page 3715 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement - Tools Required J 41712 Oil Pressure Sensor Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Page 3716 1. Apply sealant GM U.S. P/N 12346004, Canada P/N 10953480, or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. - Tighten the oil pressure sensor to 20 Nm (15 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Cover > Component Information > Specifications Oil Pump Cover: Specifications Oil Pump Cover Bolts .......................................................................................................................... ............................................... 12 Nm (106 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Technical Service Bulletins > Customer Interest for Oil Pick Up/Strainer: > 02-06-01-038 > Dec > 02 > Engine - Knocking or Lifter Noise Oil Pick Up/Strainer: Customer Interest Engine - Knocking or Lifter Noise File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-038 Date: December, 2002 TECHNICAL Subject: Engine Knock or Lifter Noise (Replace 0-Ring) Models: 2001-2002 Chevrolet Camaro 2001-2003 Chevrolet Corvette 2001-2002 Pontiac Firebird 2002-2003 Cadillac Escalade, Escalade EXT 2000-2003 Chevrolet Suburban, Tahoe 2001-2003 Chevrolet Silverado 2002-2003 Chevrolet Avalanche 2000-2003 GMC Yukon, Yukon XL 2001-2003 GMC Sierra with 4.8L, 5.3L, 5.7L or 6.0L V8 Engine (VINs V, T, Z, G, S, N, U - RPOs LR4, LM7, L59, LS1, LS6, LQ9, LQ4) Condition Some customers may comment on an engine tick noise. The distinguishing characteristic of this condition is that it likely will have been present since new, and is typically noticed within the first 161-322 km (100-200 mi). The noise may often be diagnosed as a collapsed lifter. Additionally, the noise may be present at cold start and appear to diminish and then return as the engine warms to operating temperature. This noise is different from other noises that may begin to occur at 3219-4828 km (2000-3000 mi). Cause The 0-ring seal between the oil pump screen and the oil pump may be cut, causing aeration of the oil. Correction Inspect the 0-ring seal and replace as necessary. Use the applicable part number listed below. Refer to the Engine Mechanical sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSP0. Warranty Information For vehicles repaired under warranty, use the table shown. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Technical Service Bulletins > Customer Interest for Oil Pick Up/Strainer: > 02-06-01-038 > Dec > 02 > Engine - Knocking or Lifter Noise > Page 3728 DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pick Up/Strainer: > 02-06-01-038 > Dec > 02 > Engine - Knocking or Lifter Noise Oil Pick Up/Strainer: All Technical Service Bulletins Engine - Knocking or Lifter Noise File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-01-038 Date: December, 2002 TECHNICAL Subject: Engine Knock or Lifter Noise (Replace 0-Ring) Models: 2001-2002 Chevrolet Camaro 2001-2003 Chevrolet Corvette 2001-2002 Pontiac Firebird 2002-2003 Cadillac Escalade, Escalade EXT 2000-2003 Chevrolet Suburban, Tahoe 2001-2003 Chevrolet Silverado 2002-2003 Chevrolet Avalanche 2000-2003 GMC Yukon, Yukon XL 2001-2003 GMC Sierra with 4.8L, 5.3L, 5.7L or 6.0L V8 Engine (VINs V, T, Z, G, S, N, U - RPOs LR4, LM7, L59, LS1, LS6, LQ9, LQ4) Condition Some customers may comment on an engine tick noise. The distinguishing characteristic of this condition is that it likely will have been present since new, and is typically noticed within the first 161-322 km (100-200 mi). The noise may often be diagnosed as a collapsed lifter. Additionally, the noise may be present at cold start and appear to diminish and then return as the engine warms to operating temperature. This noise is different from other noises that may begin to occur at 3219-4828 km (2000-3000 mi). Cause The 0-ring seal between the oil pump screen and the oil pump may be cut, causing aeration of the oil. Correction Inspect the 0-ring seal and replace as necessary. Use the applicable part number listed below. Refer to the Engine Mechanical sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSP0. Warranty Information For vehicles repaired under warranty, use the table shown. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pick Up/Strainer: > 02-06-01-038 > Dec > 02 > Engine - Knocking or Lifter Noise > Page 3734 DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Technical Service Bulletins > Page 3735 Oil Pick Up/Strainer: Specifications Oil Pump Screen Nut ........................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Oil Pump Screen Bolt ....................................... ................................................................................................................................... 12 Nm (106 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Technical Service Bulletins > Page 3736 Oil Pick Up/Strainer: Service and Repair Oil Pumps, Pump Screen and Deflector Replacement Removal Procedure 1. Remove the oil pan. 2. Remove the engine front cover. 3. Remove the oil pump screen bolt and nuts. 4. Remove the oil pump screen with O-ring seal. 5. Remove the O-ring seal from the pump screen. 6. Discard the O-ring seal. 7. Remove the remaining crankshaft oil deflector nuts. 8. Remove the crankshaft oil deflector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Technical Service Bulletins > Page 3737 9. Remove the oil pump bolts. Important: Do not allow dirt or debris to enter the oil pump assembly, cap end as necessary. 10. Remove the oil pump. 11. Clean and inspect the oil pump. Installation Procedure 1. Align the splined surfaces of the crankshaft sprocket and the oil pump drive gear and install the oil pump. 2. Install the oil pump onto the crankshaft sprocket until the pump housing contacts the face of the engine block. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the oil pump bolts. - Tighten the oil pump bolts to 25 Nm (18 ft. lbs.). 4. Install the crankshaft oil deflector and nuts until snug. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Technical Service Bulletins > Page 3738 5. Lubricate a NEW oil pump screen O-ring seal with clean engine oil. 6. Install the NEW O-ring seal onto the oil pump screen. Important: Push the oil pump screen tube completely into the oil pump prior to tightening the bolt. Do not allow the bolt to pull the tube into the pump. 7. Align the oil pump screen mounting brackets with the correct crankshaft bearing cap studs. 8. Install the oil pump screen. 9. Install the oil pump screen bolt and nuts. 9.1. Tighten the oil pump screen bolt to 12 Nm (106 inch lbs.). 9.2. Tighten the crankshaft oil deflector/oil pump screen nuts to 25 Nm (18 ft. lbs.). 10. Install the engine front cover. 11. Install the oil pan. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure Minimum - Hot At 1,000 Revolutions Per Minute (RPM) ...................................................................................................................................................... 41 kPa (6 psig) At 2,000 RPM .................................................................................................................. .......................................................................... 124 kPa (18 psig) At 4,000 RPM .............................. .............................................................................................................................................................. 165 kPa (24 psig) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 3743 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing - Tools Required J 21867 Pressure Gauge - J 42907 Oil Pressure Testing Tool 1. With the vehicle on a level surface, run the vehicle for a few minutes, allow adequate drain down time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gauge or light. 4. Listen for a noisy valve train or a knocking noise. 5. Inspect for the following: - Oil diluted by water or glycol anti freeze - Foamy oil 6. Remove the oil filter and install the J 42907. 7. install J21867 or equivalent to the J42907. 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to Engine Mechanical Specifications. 10. If the engine oil pressure is below specifications, inspect the engine for one or more of the following: - Oil pump worn or dirty. - Oil pump-to-engine block bolts loose. - Oil pump screen loose, plugged, or damaged - Oil pump screen O-ring seal missing or damaged - Malfunctioning oil pump pressure regulator valve - Excessive bearing clearance - Cracked, porous, or restricted oil galleries - Oil gallery plugs missing or incorrectly installed. - Broken valve lifters Repair as necessary 11. If the oil pressure reading on the J 21867 or equivalent is within specifications, inspect for the following: - Plugged or incorrect oil filter and/or malfunctioning oil bypass valve - Malfunctioning oil pressure gauge or sensor Repair as necessary Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Specifications Oil Pressure Regulator Valve: Specifications Oil Pump Relief Valve Plug ................................................................................................................. ............................................... 12 Nm (106 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC Intake Manifold: Customer Interest Brakes - 'Reduced Brake Power' Shown on DIC File In Section: 05 - Brakes Bulletin No.: 02-05-23-004 Date: October, 2002 TECHNICAL Subject: Driver's Information Center (DIC) "Reduced Brake Power" Message, Reduced Vacuum Boost (Inspect/Replace Intake Manifold and Recalibrate the Instrument Panel Cluster (IPC)) Models: 2002-2003 Cadillac Escalade 2WD 2002-2003 Chevrolet Avalanche 1500 Series, Silverado, Suburban, Tahoe 2002-2003 GMC Sierra, Yukon, Yukon XL with Power Vacuum Boost Brake System (RPOs JC3 and JC4) Condition Some customers may comment on a "Reduced Brake Power" message on the DIC. Cause It is possible that a very small number of 2002 and 2003 model year vehicles may have a restriction in the vacuum booster port on the intake manifold. On the 2003 model year, only the IPC calibration is the cause of the DIC message. Correction Important: Only inspect suspect vehicles built between June 13, 2002 and August 9, 2002. Follow the service procedure to diagnose and correct this condition. 1. Open the hood and install fender covers. 2. Loosen the engine sight shield bolt. The bolt should stay in the shield. 3. Remove the engine sight shield from the sight shield retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 3755 4. Inspect the left front corner of the intake manifold for a "C" with a circle around it (2). ^ If the intake manifold DOES have a "C" (2) on it, continue with Step 5. ^ If the intake manifold DOES NOT have a "C" (2) on it, continue with Step 19. 5. Disconnect the accelerator control cable clip from the engine sight shield retainer. 6. Disconnect the cruise control cable clip from the retainer if equipped. 7. Remove the engine sight shield retainer bolts and the retainer if equipped. 8. Inspect rear center of the intake manifold just below the recycle symbol for "MADE IN CANADA" (2). ^ If the intake manifold DOES have "MADE IN CANADA" (1) on it, continue with Step 9 ^ If the intake manifold DOES NOT have "MADE IN CANADA" (1) on it, continue with Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 3756 9. Locate the vacuum booster port connector (1) on the left rear of the intake manifold. 10. Gently pull out on the vacuum booster hose (2). 11. With two fingers, push in the vacuum booster port connector lock ring (3) while gently pulling out on the vacuum booster hose (2). Important: ^ DO NOT force the drill bit into the vacuum booster intake port. ^ If the vacuum booster intake port is restricted, DO NOT attempt to remove the restriction with the drill bit. ^ If the restriction is removed with the drill bit, the material from the restriction may cause internal engine damage. ^ If the vacuum booster port is restricted, the intake manifold must be replaced. 12. Inspect the vacuum booster intake port with a 8.7 mm (11/32 in) drill bit, maximum length of 127 mm (5 in). 13. Insert the drill bit approximately 63.5 mm (2.5 in) into the vacuum booster intake port. ^ If the vacuum booster intake port IS restricted, continue with Step 14. ^ If the vacuum booster intake port IS NOT restricted, continue with Step 15. 14. Replace the intake manifold. Refer to Intake Manifold Replacement (SI Document ID # 753666). 15. Reinstall the vacuum booster hose to the vacuum booster intake port by pushing to hose nipple into the connector. 16. Install the engine sight shield retainer and the bolts. Tighten Tighten the engine sight shield retainer bolts to 5 N.m (44 lb in). 17. Install the cruise control cable clip to the retainer. 18. Install the accelerator control cable clip to the retainer if equipped. 19. Install the engine sight shield to the retainer if equipped. Tighten Tighten the engine sight shield bolt to 10 N.m (89 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 3757 20. Start the engine and fully apply the brakes four or five times in order to ensure a "good" brake pedal. Recalibrating the IPC (2003 Model Year Vehicles) 1. Vehicles Built Prior To the following VIN Breakpoints ^ 3G104569 ^ 3E117608 ^ 31118369 ^ 3Z120443 ^ 3R107568 ^ 3J101720 2. Plug in Tech 2. 3. Set the parking brake and turn the ignition ON with the engine off. 4. Reprogram the IPC following normal SPS procedures (TIS Version 9 released August 2002 or newer). 5. After reprogramming the IPC, start the vehicle and fully apply the brakes four to five times in order to ensure a "good" brake pedal and that there are no messages on the DIC. Important: The Owner's Manual Must Be Replaced After The IPC Is Recalibrated. ^ A new Owner's Manual can be ordered from Helm @ 1-800-551-4123. The dealer will be billed for the new Manual and reimbursed through the warranty claims system. ^ The Owner's Manual will be shipped to the dealer. Dealers will be required to mail the Manual to the customer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 3758 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 00-06-01-026C > Feb > 10 > Engine Intake Manifold Inspection/Replacement Intake Manifold: All Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 02-05-23-004 > Oct > 02 > Brakes 'Reduced Brake Power' Shown on DIC Intake Manifold: All Technical Service Bulletins Brakes - 'Reduced Brake Power' Shown on DIC File In Section: 05 - Brakes Bulletin No.: 02-05-23-004 Date: October, 2002 TECHNICAL Subject: Driver's Information Center (DIC) "Reduced Brake Power" Message, Reduced Vacuum Boost (Inspect/Replace Intake Manifold and Recalibrate the Instrument Panel Cluster (IPC)) Models: 2002-2003 Cadillac Escalade 2WD 2002-2003 Chevrolet Avalanche 1500 Series, Silverado, Suburban, Tahoe 2002-2003 GMC Sierra, Yukon, Yukon XL with Power Vacuum Boost Brake System (RPOs JC3 and JC4) Condition Some customers may comment on a "Reduced Brake Power" message on the DIC. Cause It is possible that a very small number of 2002 and 2003 model year vehicles may have a restriction in the vacuum booster port on the intake manifold. On the 2003 model year, only the IPC calibration is the cause of the DIC message. Correction Important: Only inspect suspect vehicles built between June 13, 2002 and August 9, 2002. Follow the service procedure to diagnose and correct this condition. 1. Open the hood and install fender covers. 2. Loosen the engine sight shield bolt. The bolt should stay in the shield. 3. Remove the engine sight shield from the sight shield retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 02-05-23-004 > Oct > 02 > Brakes 'Reduced Brake Power' Shown on DIC > Page 3768 4. Inspect the left front corner of the intake manifold for a "C" with a circle around it (2). ^ If the intake manifold DOES have a "C" (2) on it, continue with Step 5. ^ If the intake manifold DOES NOT have a "C" (2) on it, continue with Step 19. 5. Disconnect the accelerator control cable clip from the engine sight shield retainer. 6. Disconnect the cruise control cable clip from the retainer if equipped. 7. Remove the engine sight shield retainer bolts and the retainer if equipped. 8. Inspect rear center of the intake manifold just below the recycle symbol for "MADE IN CANADA" (2). ^ If the intake manifold DOES have "MADE IN CANADA" (1) on it, continue with Step 9 ^ If the intake manifold DOES NOT have "MADE IN CANADA" (1) on it, continue with Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 02-05-23-004 > Oct > 02 > Brakes 'Reduced Brake Power' Shown on DIC > Page 3769 9. Locate the vacuum booster port connector (1) on the left rear of the intake manifold. 10. Gently pull out on the vacuum booster hose (2). 11. With two fingers, push in the vacuum booster port connector lock ring (3) while gently pulling out on the vacuum booster hose (2). Important: ^ DO NOT force the drill bit into the vacuum booster intake port. ^ If the vacuum booster intake port is restricted, DO NOT attempt to remove the restriction with the drill bit. ^ If the restriction is removed with the drill bit, the material from the restriction may cause internal engine damage. ^ If the vacuum booster port is restricted, the intake manifold must be replaced. 12. Inspect the vacuum booster intake port with a 8.7 mm (11/32 in) drill bit, maximum length of 127 mm (5 in). 13. Insert the drill bit approximately 63.5 mm (2.5 in) into the vacuum booster intake port. ^ If the vacuum booster intake port IS restricted, continue with Step 14. ^ If the vacuum booster intake port IS NOT restricted, continue with Step 15. 14. Replace the intake manifold. Refer to Intake Manifold Replacement (SI Document ID # 753666). 15. Reinstall the vacuum booster hose to the vacuum booster intake port by pushing to hose nipple into the connector. 16. Install the engine sight shield retainer and the bolts. Tighten Tighten the engine sight shield retainer bolts to 5 N.m (44 lb in). 17. Install the cruise control cable clip to the retainer. 18. Install the accelerator control cable clip to the retainer if equipped. 19. Install the engine sight shield to the retainer if equipped. Tighten Tighten the engine sight shield bolt to 10 N.m (89 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 02-05-23-004 > Oct > 02 > Brakes 'Reduced Brake Power' Shown on DIC > Page 3770 20. Start the engine and fully apply the brakes four or five times in order to ensure a "good" brake pedal. Recalibrating the IPC (2003 Model Year Vehicles) 1. Vehicles Built Prior To the following VIN Breakpoints ^ 3G104569 ^ 3E117608 ^ 31118369 ^ 3Z120443 ^ 3R107568 ^ 3J101720 2. Plug in Tech 2. 3. Set the parking brake and turn the ignition ON with the engine off. 4. Reprogram the IPC following normal SPS procedures (TIS Version 9 released August 2002 or newer). 5. After reprogramming the IPC, start the vehicle and fully apply the brakes four to five times in order to ensure a "good" brake pedal and that there are no messages on the DIC. Important: The Owner's Manual Must Be Replaced After The IPC Is Recalibrated. ^ A new Owner's Manual can be ordered from Helm @ 1-800-551-4123. The dealer will be billed for the new Manual and reimbursed through the warranty claims system. ^ The Owner's Manual will be shipped to the dealer. Dealers will be required to mail the Manual to the customer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 02-05-23-004 > Oct > 02 > Brakes 'Reduced Brake Power' Shown on DIC > Page 3771 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 00-06-01-026C > Feb > 10 > Engine - Intake Manifold Inspection/Replacement Intake Manifold: All Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Engine Mechanical Specifications (Unit Repair) Intake Manifold: Specifications Engine Mechanical Specifications (Unit Repair) Intake Manifold Intake Manifold Cylinder Head Deck Flatness (Measured within a 200 mm (7.87 inch)Area that Includes Two Runner Port Openings). .............. 0.3 mm (0.118 inch) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Engine Mechanical Specifications (Unit Repair) > Page 3779 Intake Manifold: Specifications Fastener Tightening Specifications Intake Manifold Bolt First Pass in Sequence ........................................................................................................................ ................................................. 5 Nm (44 inch lbs.) Final Pass in Sequence ...................................... ................................................................................................................................ 10 Nm (89 inch lbs.) Intake Manifold Sight Shield Bolt (RPO LQ9 - 6.0L Engine) ................................................................................................................ 9 Nm (80 inch lbs.) Intake Manifold Sight Shield Bolt (4.8L, 5.3L, and RPO LQ4) ............................................................................................................ 10 Nm (89 inch lbs.) Intake Manifold Sight Shield Retainer Bolt ............................................................................................................................................ 5 Nm (44 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Engine Sight Shield Replacement Intake Manifold: Service and Repair Engine Sight Shield Replacement Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L (LQ4) Removal Procedure 1. Loosen the intake manifold sight shield bolt. 2. Remove the sight shield from the sight shield retainer. 3. If removal of the sight shield retainer is required, disconnect the accelerator control cable clip from the retainer. 4. Disconnect the cruise control cable clip from the retainer. 5. Remove the sight shield retainer bolts and the retainer, if required. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Engine Sight Shield Replacement > Page 3782 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the sight shield retainer and the bolts, if required. - Tighten the retainer bolts to 5 Nm (44 inch lbs.). 2. Install the cruise control cable clip to the retainer. 3. Install the accelerator control cable clip to the retainer. Notice: Use care when installing the engine sight shield to avoid contacting the manifold absolute pressure (MAP) sensor wire harness connector. Loss of engine performance or engine damage may result. 4. Install the intake manifold sight shield to the retainer. - Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Engine Sight Shield Replacement > Page 3783 Intake Manifold: Service and Repair Intake Manifold Replacement Intake Manifold Replacement Removal Procedure Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly. 1. Remove the throttle body. 2. Remove the fuel injectors. 3. Disconnect the following electrical connectors: - Manifold absolute pressure (MAP) sensor (1) - Knock sensor (2) - Exhaust gas recirculation (EGR) valve, if equipped. 4. Remove the knock sensor harness electrical connector from the intake manifold. 5. Set the electrical harness aside. 6. If equipped, remove the following EGR pipe bolts: - Intake manifold (1) - Cylinder head (2) - Exhaust manifold (3) 7. If equipped, remove the EGR pipe with valve. 8. If equipped, remove the EGR pipe gasket from the exhaust manifold. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Engine Sight Shield Replacement > Page 3784 9. If equipped with vacuum assisted brakes, remove the vacuum brake booster hose from the rear of the intake manifold. 10. Remove the positive crankcase ventilation (PCV) hose with valve. 11. Remove the MAP sensor (1) from the intake manifold. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Engine Sight Shield Replacement > Page 3785 12. Remove the accelerator control cable bracket bolts (1). 13. Remove the accelerator control cable bracket (2) from the intake manifold. 14. Remove the evaporative emission (EVAP) purge solenoid vent tube by performing the following: 14.1. Remove the EVAP tube end (2) from the solenoid (1). 14.2. Squeeze the EVAP pipe quick connect fitting (3) retainer together. 14.3. Remove the EVAP tube end (3) from the vapor pipe. 15. Remove the EVAP purge solenoid bolt (2), solenoid (3), and isolator (1) from the intake manifold. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Engine Sight Shield Replacement > Page 3786 16. Remove the intake manifold bolts. 17. Remove the intake manifold. 18. Remove the intake manifold gaskets (1) from the intake manifold. 19. Discard the old intake manifold gaskets. 20. Clean and inspect the intake manifold. 21. If equipped with EGR, clean the gasket surfaces of the EGR pipe and the exhaust manifold. Installation Procedure 1. Install new intake manifold gaskets (1) to the intake manifold. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Engine Sight Shield Replacement > Page 3787 2. Install the intake manifold. 3. Apply a 5 mm (0.20 inch) band of threadlock GM U.S. P/N 12345382, Canada P/N 10953489, or equivalent to the threads of the intake manifold bolts. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the intake manifold bolts. 4.1. Tighten the intake manifold bolts a first pass in sequence to 5 Nm (44 inch lbs.). 4.2. Tighten the intake manifold bolts a final pass in sequence to 10 Nm (89 inch lbs.). 5. install the EVAP purge solenoid (3), isolator (1), and bolt (2) to the intake manifold. - Tighten the EVAP purge solenoid bolt to 10 Nm (89 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Engine Sight Shield Replacement > Page 3788 6. Install the EVAP purge solenoid vent tube to the solenoid (1) and vapor pipe. 7. Install the accelerator control cable bracket (2) to the intake manifold. 8. Install the accelerator control cable bracket bolts (1). - Tighten the accelerator control cable bracket bolts to 10 Nm (89 inch lbs.). Important: Lightly coat the MAP sensor seal with clean engine oil before installing. 9. Install the MAP sensor (1) to the intake manifold. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Engine Sight Shield Replacement > Page 3789 10. Install the PCV hose with valve. 11. If equipped with vacuum assisted brakes, install the vacuum brake booster hose to the rear of the intake manifold. 12. If equipped, position a new EGR pipe gasket on the exhaust manifold. 13. If equipped, install the EGR pipe with valve. 14. If equipped, install the following EGR pipe bolts until snug: - Intake manifold (1) - Cylinder head (2) - Exhaust manifold (3) 15. If equipped, tighten the EGR pipe bolts. - Tighten the EGR valve pipe-to-intake manifold bolts to 10 Nm (89 inch lbs.). - Tighten the EGR valve pipe-to-cylinder head bolts to 50 Nm (37 ft. lbs.). - Tighten the EGR valve pipe-to-exhaust manifold bolts to 30 Nm (22 ft. lbs.). 16. Route the electrical harness into position over the engine. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Engine Sight Shield Replacement > Page 3790 17. Connect the knock sensor harness electrical connector to the intake manifold. 18. Connect the following electrical connectors. - MAP sensor (1) - Knock sensor (2) - EGR valve, if equipped 19. Install the fuel injectors. 20. Install the throttle body. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3796 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3797 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3798 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3799 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3800 Oil Pressure Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3801 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3802 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3803 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3804 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3805 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3806 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3807 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3808 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3809 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3810 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3811 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3812 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3813 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3814 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3815 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3816 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3817 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3818 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3819 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3820 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3821 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3822 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3823 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3824 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3825 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3826 Oil Pressure Gauge: Electrical Diagrams For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Diagrams. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Page 3827 Oil Pressure Gauge: Description and Operation ENGINE OIL PRESSURE GAGE The IPC uses the engine oil sensor signal to determine the engine oil pressure. The oil pressure sensor signal circuit is hard-wired to the IPC. The engine oil pressure sensor signal to the IPC is a variable resistance ranging from 0-90 Ohms. The sensor resistance is used to drive the engine oil pressure gage. A sensor resistance of 1 Ohm will display as 0 kPa (0 psi) and a resistance of 88 Ohms will display as 550 kPa (80 psi). The IPC monitors the oil pressure sensor signal circuit in order to decide when the oil pressure is too low. The Check Engine Oil Pressure indicator will be displayed in the message center if the IPC detects a low engine oil pressure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Page 3828 Oil Pressure Gauge: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Testing and Inspection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications Crankshaft Main Bearing Seal: Specifications Crankshaft Oil Deflector Nuts .............................................................................................................. .................................................... 25 Nm (18 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications > Page 3833 Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement - Tools Required J 41479 Crankshaft Rear Oil Seal Installer Removal Procedure 1. Remove the engine flywheel. 2. Remove the crankshaft rear oil seal (1) from the rear cover. Installation Procedure Important: The flywheel spacer (if applicable) must be removed prior to oil seal installation. - Do not lubricate the oil seal inside diameter (ID) or the crankshaft surface. - Do not reuse the crankshaft rear oil seal. 1. Lubricate the outside diameter (OD) of the oil seal (1) with clean engine oil. DO NOT allow oil or other lubricants to contact the seal surface. 2. Lubricate the rear cover oil seal bore with clean engine oil. DO NOT allow oil or other lubricants to contact the crankshaft surface. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications > Page 3834 3. Install the J 41479 tapered cone (2) and bolts onto the rear of the crankshaft. 4. Tighten the bolts until snug. Do not overtighten. 5. Install the rear oil seal onto the tapered cone (2) and push the seal to the rear cover bore. 6. Thread the J 41479 threaded rod into the tapered cone until the tool (1) contacts the oil seal. 7. Align the oil seal into the tool (1). 8. Rotate the handle of the tool (1) clockwise until the seal enters the rear cover and bottoms into the cover bore. 9. Remove the J 41479. 10. Install the engine flywheel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Exhaust Manifold Gasket > Component Information > Service and Repair Exhaust Manifold Gasket: Service and Repair Exhaust Seal Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the engine shield bolts and shield, if necessary. 3. Remove the oil pan skid plate bolts and plate, if necessary. 4. Disconnect the CPA retainer. 5. Disconnect the oxygen sensor electrical connector (1). 6. Support the catalytic converter or exhaust manifold pipe with adjustable jackstands. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Exhaust Manifold Gasket > Component Information > Service and Repair > Page 3838 7. Remove the right exhaust manifold pipe nuts. 8. Remove the left exhaust manifold pipe nuts. 9. Remove the exhaust hanger mounting bracket bolts. 10. Lower the catalytic converter or exhaust manifold pipe using the adjustable jackstands. 11. Remove the exhaust manifold pipe seal(s). Installation Procedure 1. Install the exhaust manifold pipe seal(s). 2. Raise the catalytic converter or exhaust manifold pipe using the adjustable jackstands. 3. Install the exhaust hanger mounting bracket bolts. Notice: Refer to Fastener Notice in Cautions and Notices. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Exhaust Manifold Gasket > Component Information > Service and Repair > Page 3839 4. Install the left exhaust manifold pipe nuts. - Tighten the transmission bolts to 100 Nm (74 ft. lbs.). - Tighten the exhaust pipe hanger bracket bolts to 12 Nm (106 inch lbs.). - Tighten the exhaust manifold pipe nuts to 50 Nm (39 ft. lbs.). 5. Install the right exhaust manifold pipe nuts. - Tighten the nuts to 50 Nm (39 ft. lbs.). 6. Connect the oxygen sensor electrical connector (1). 7. Connect the CPA retainer. 8. Remove the adjustable jackstands from catalytic converter or exhaust manifold pipe. 9. Install the oil pan skid plate and bolts, if necessary. - Tighten the bolts to 20 Nm (15 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Exhaust Manifold Gasket > Component Information > Service and Repair > Page 3840 10. Install the engine shield and bolts, if necessary. - Tighten the bolts to 20 Nm (15 ft. lbs.). 11. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement - Tools Required J 41478 Crankshaft Front Oil Seal Installer Removal Procedure 1. Remove the crankshaft balancer. 2. Remove the crankshaft oil seal (1) from the front cover. Installation Procedure Important: Do not lubricate the oil seal sealing surface. - Do not reuse the crankshaft oil seal. 1. Lubricate the outer edge of the oil seal (1) with clean engine oil. 2. Lubricate the front cover oil seal bore with clean engine oil. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 3844 3. Install the crankshaft front oil seal onto the J 41478 guide. 4. Install the J 41478 threaded rod (with nut, washer, guide, and oil seal) into the end of the crankshaft. 5. Use the J41478 in order to install the oil seal into the cover bore. 5.1. Use a wrench and hold the hex on the installer bolt. 5.2. Use a second wrench and rotate the installer nut clockwise until the seal bottoms in the cover bore. 5.3. Remove the J41478. 5.4. Inspect the oil seal for proper installation. The oil seal should be installed evenly and completely into the front cover bore. 6. Install the crankshaft balancer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-04-029A > Jun > 05 > Engine Rough Idle/Misfire/MIL ON/DTC P0300 Intake Manifold Gasket: Customer Interest Engine - Rough Idle/Misfire/MIL ON/DTC P0300 Bulletin No.: 05-06-04-029A Date: June 24, 2005 TECHNICAL Subject: Flexible Fuel (RPO L59) Rough Idle, Misfire, MIL DTC P0300 (Install Intake Manifold Gaskets With Teal Green Gasket Material) Models: 2002-2004 Chevrolet Silverado, Suburban, Tahoe 2002-2004 GMC Sierra, Yukon, Yukon XL with 5.3L Engine and Flexible Fuel (VIN Z - RPO L59) This bulletin may apply to the following engines using regular fuel: 4.8L, 5.3L, 6.0L (VINs V, T, P, U, N - RPOs LR4, LM7, LM4, LQ4, LQ9). Supercede: This bulletin is being revised to add additional diagnostic information. Please discard Corporate Bulletin Number 05-06-04-029 (Section 06 - Engine/Propulsion System). Important: Always begin your diagnosis with the Diagnostic System Check - Engine Controls (SI Document ID # 1289827) for any MIL or driveability concern. The Diagnostic System Check directs you to the next logical step in your diagnosis. Follow the instructions in this bulletin should the rough idle, misfire, or DTC P0300 diagnostic procedure point to an air leak in the intake manifold gasket. Following the published diagnostic procedures will improve diagnostic accuracy and support our fix it right the first time approach. Condition Some customers may comment that the vehicle may have a rough idle, misfires and/or a MIL illuminated with a stored DTC P0300. Cause The L59 engine is calibrated for ethanol fuel (E85). Due to the low volatility of ethanol, the PCM provides higher fuel flow through the injector, which may pool on the upper manifold to head gasket material. Overtime (usually 12 months and longer), the gasket material may degrade resulting in an unmetered air leak. Correction Replace the upper intake manifold gaskets with the teal green gasket material, P/N 89017589. Important: Do not replace the upper intake manifold gaskets with the original orange gasket material, P/N 17113557. Inspect Intake Manifold to Cylinder head Deck for Warpage Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-04-029A > Jun > 05 > Engine Rough Idle/Misfire/MIL ON/DTC P0300 > Page 3853 Important: The intake plenum should also be checked for excessive warpage that may cause an uneven clamping pressure of the seal. If the plenum is found to be warped it will need to be replaced. Service Information states, "An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area should be replaced." Intake warpage is measured at the gasket sealing surfaces and should be measured within a 200 mm (7.87 in) area. This measurement is across only two of the intake runner port openings. Measurements taken across the entire distance of all four intake runner ports will lead to unnecessary manifold replacements. Important: Measurements taken across the entire distance of all four intake runner ports will lead to unnecessary intake manifold replacements. 1. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across two runner port openings. 2. Insert a feeler gauge between the intake manifold and the straight edge. An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced. Do not replace intake manifolds with warpage that measures less than 3 mm (0.118 in) over a 200 mm (7.87 in). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-04-029A > Jun > 05 > Engine Rough Idle/Misfire/MIL ON/DTC P0300 > Page 3854 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-04-029A > Jun > 05 > Engine - Rough Idle/Misfire/MIL ON/DTC P0300 Intake Manifold Gasket: All Technical Service Bulletins Engine - Rough Idle/Misfire/MIL ON/DTC P0300 Bulletin No.: 05-06-04-029A Date: June 24, 2005 TECHNICAL Subject: Flexible Fuel (RPO L59) Rough Idle, Misfire, MIL DTC P0300 (Install Intake Manifold Gaskets With Teal Green Gasket Material) Models: 2002-2004 Chevrolet Silverado, Suburban, Tahoe 2002-2004 GMC Sierra, Yukon, Yukon XL with 5.3L Engine and Flexible Fuel (VIN Z - RPO L59) This bulletin may apply to the following engines using regular fuel: 4.8L, 5.3L, 6.0L (VINs V, T, P, U, N - RPOs LR4, LM7, LM4, LQ4, LQ9). Supercede: This bulletin is being revised to add additional diagnostic information. Please discard Corporate Bulletin Number 05-06-04-029 (Section 06 - Engine/Propulsion System). Important: Always begin your diagnosis with the Diagnostic System Check - Engine Controls (SI Document ID # 1289827) for any MIL or driveability concern. The Diagnostic System Check directs you to the next logical step in your diagnosis. Follow the instructions in this bulletin should the rough idle, misfire, or DTC P0300 diagnostic procedure point to an air leak in the intake manifold gasket. Following the published diagnostic procedures will improve diagnostic accuracy and support our fix it right the first time approach. Condition Some customers may comment that the vehicle may have a rough idle, misfires and/or a MIL illuminated with a stored DTC P0300. Cause The L59 engine is calibrated for ethanol fuel (E85). Due to the low volatility of ethanol, the PCM provides higher fuel flow through the injector, which may pool on the upper manifold to head gasket material. Overtime (usually 12 months and longer), the gasket material may degrade resulting in an unmetered air leak. Correction Replace the upper intake manifold gaskets with the teal green gasket material, P/N 89017589. Important: Do not replace the upper intake manifold gaskets with the original orange gasket material, P/N 17113557. Inspect Intake Manifold to Cylinder head Deck for Warpage Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-04-029A > Jun > 05 > Engine - Rough Idle/Misfire/MIL ON/DTC P0300 > Page 3860 Important: The intake plenum should also be checked for excessive warpage that may cause an uneven clamping pressure of the seal. If the plenum is found to be warped it will need to be replaced. Service Information states, "An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area should be replaced." Intake warpage is measured at the gasket sealing surfaces and should be measured within a 200 mm (7.87 in) area. This measurement is across only two of the intake runner port openings. Measurements taken across the entire distance of all four intake runner ports will lead to unnecessary manifold replacements. Important: Measurements taken across the entire distance of all four intake runner ports will lead to unnecessary intake manifold replacements. 1. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across two runner port openings. 2. Insert a feeler gauge between the intake manifold and the straight edge. An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced. Do not replace intake manifolds with warpage that measures less than 3 mm (0.118 in) over a 200 mm (7.87 in). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-04-029A > Jun > 05 > Engine - Rough Idle/Misfire/MIL ON/DTC P0300 > Page 3861 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3867 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3868 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3869 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 3874 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3879 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3880 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3885 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3886 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3887 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 3892 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3897 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3898 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3899 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration Wheels: All Technical Service Bulletins Wheels/Tires - Slow Tire Leak/Vibration Bulletin No.: 03-03-10-001D Date: January 17, 2008 TECHNICAL Subject: Tire Slowly Goes Flat and/or Excessive wheel Vibration Caused By Bead Splits (Replace wheels with New Heavy Duty Rim Version) Models: 1999-2006 Chevrolet Silverado 1500 Series Pickup Models (Classic) 1999-2006 Chevrolet Express 1500 Series Vans 2000-2006 Chevrolet Suburban Tahoe 1999-2006 GMC Sierra 1500 Series Pickup Models (Classic) 1999-2006 GMC Savana 1500 Series Vans 2002-2006 GMC Yukon Yukon XL 2007 GMC Sierra Denali Crew Cab with 6-Bolt, 16 X 6.5 Full Face Steel wheel (Base and RPO PY2) Supercede: This bulletin is being revised to add the Express and Savana models and add information to the Correction section. Please discard Corporate Bulletin Number 03-03-10-001C (Section 03 Suspension). Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on a tire that slowly goes flat and/or excessive wheel vibration. This condition is more apparent on vehicles in which customer usage typically involves frequent severe conditions such as: High load (at or above gross vehicle weight) Rough road/off road usage Fleet/Commercial usage Cause The wheel may experience a crack or split in the outboard bead seat weld area. A weld attaches the rim and disc together on full-face wheels in this area. To identify this wheel it is offered in a silver painted version P/N 9593915 code "TZA" and a chrome-clad version, P/N 9593150 code "RSC" (these codes are stamped into the wheel's disc near the bolt holes). Correction Wheel replacement should only be done for air loss and/or vibration caused by bead splits. A new heavy-duty rim version of these wheels has been released for service. The new heavy-duty painted wheel is P/N 9595245 code "FFU" used as a road wheel and spare. The new heavy-duty chrome clad version is P/N 9595306 code "FFW" used as a road wheel only (these codes are stamped into the inboard rim flange balance weight area and are also on a sticker near the bolt holes). If a condition of a crack or split as described above occurs all (5) five of the original wheels on the vehicle should be replaced with the new heavy-duty wheels as follows: Replace road wheel P/N 9593915 with P/N 9595245. Replace road wheel PIN 9593150 with P/N 9595306. Replace the spare wheel with P/N 9595245 on all vehicles. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration > Page 3908 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3914 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3915 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3916 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 3921 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3926 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3927 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3932 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3933 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3934 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 3939 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3944 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3945 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3946 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold Gasket: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration > Page 3955 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Specifications Valve Guide Seal: Specifications Valve System Valve Stem Clearance (Production-Exhaust) .............................................................................................................. 0.025-0.066 mm (0.001-0.0026 inch) Valve Stem Clearance (Production-Intake) ................................................................................................................. 0.025-0.066 mm (0.001-0.0026 inch) Valve Stem Clearance (Service-Exhaust) ................................................................................................ 0.093 mm (Maximum) (0.0037 inch (Maximum)) Valve Stem Clearance (Service-Intake) ................................................................................................... 0.093 mm (Maximum) (0.0037 inch (Maximum)) Valve Stem Diameter (Production) ............................................................................................................................. 7.955-7.976 mm (0.3132-0 314 inch) Valve Stem Diameter (Service) ..................................................................................................................... 7.95 mm (Minimum) (0.313 inch (Minimum)) Valve Stem Oil Seal Installed Height (Measured from the Valve Spring Shim to Top Edge of Seal Body - First Design Seal) ..................... 18.1-19.1 mm (0.712-0.752 inch) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Specifications > Page 3959 Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement - Tools Required - J 22794 Spark Plug Port Adapter - J 38606 Valve Spring Compressor - J 42078 Valve Stem Oil Seal Installer Removal Procedure 1. Remove the valve rocker arm. 2. Disconnect the spark plug wire at the spark plug. - Twist each plug wire boot 1/2 turn. - Pull only on the boot in order to remove the wire from the spark plug. Important: Remove the spark plugs from the cylinder head with the engine at room temperature. 3. Loosen the spark plug 1 or 2 turns. 4. Brush or air blast away any dirt or debris from around the spark plug. 5. Remove the spark plug. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Specifications > Page 3960 6. Install J 22794 into the spark plug hole. 7. Attach an air hose to J22794. 8. Apply compressed air to J 22794 in order to hold the valves in place. 9. Use J 38606 in order to compress the valve spring. 10. Remove the valve stem keys (3). 11. Carefully release the valve spring tension. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Specifications > Page 3961 12. Remove the J 38606. 13. Remove the valve spring cap (4). 14. Remove the valve spring (5). Important: A second design valve stem oil seal and shim may be used on later engines. A separate spring shim is not required with the second design seal and shim. 15. Remove the valve stem oil seal (6) (first design). 16. Remove the valve spring shim (7) (first design). 17. Remove the valve stem oil seal and shim (2) (second design) Installation Procedure 1. Clean the cylinder head valve spring seat and/or shim area. 2. Install the valve spring shim (7) (first design). 3. Install the valve stem oil seal and shim (2) (second design). J42078 is not required for installation of the second design seal and shim. Important: The valve stem oil seal alignment and position on the valve guide is critical. An improperly installed valve stem oil seal may lead to excessive oil consumption, increased vehicle emissions, or component damage. 4. Install the valve stem oil seal (first design) onto the guide. 4.1. Lubricate the valve guide and valve stem oil seal with clean engine oil. 4.2. Install the valve stem oil seal (first design) onto the valve stem. Push the seal down until the seal contacts the valve guide. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Specifications > Page 3962 4.3. Use the J 42078 in order to install the valve stem oil seal. Push or lightly tap the tool until the tool bottoms against the valve spring shim. 5. Measure the valve stem oil seals (first design) for the properly installed height. There should be a 18.1 - 19.1 mm (0.712 - 0.752 inch) gap between the top edge of the oil seal body and the valve spring shim surface. 6. Install the valve spring (5). 7. Install the valve spring cap (4). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Specifications > Page 3963 8. Compress the valve spring using the J 38606. 9. Install the valve keys. - Use grease in order to hold the valve keys in place. - Make sure the keys seat properly in the groove of the valve stem. - Carefully release the valve spring pressure, making sure the valve keys stay in place. - Remove the J 38606. - Tap the end of the valve stem with a plastic faced hammer to seat the keys (if necessary). 10. Remove J 22794 from the spark plug port. Notice: Refer to Fastener Notice in Service Precautions. 11. Hand start the spark plug. - Tighten the spark plug to 15 Nm (11 ft. lbs.). 12. Install the spark plug wires at the ignition coil. 13. Install the spark plug wire to the spark plug. 14. Inspect the wires for proper installation: - Push sideways on each boot in order to check for proper installation. - Reinstall any loose boot. 15. Install the valve rocker arm. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Specifications Oil Level Sensor: Specifications Oil Level Sensor .................................................................................................................................. ................................................ 13 Nm (115 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Specifications > Page 3968 Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Drain the engine oil. 2. Disconnect the oil level sensor electrical connector (6). 3. Remove the oil level sensor from the oil pan. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the oil level sensor to the oil pan. - Tighten the oil level sensor to 13 Nm (115 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Specifications > Page 3969 2. Connect the oil level sensor electrical connector (6). 3. Fill the engine oil. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Page 3976 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement - Tools Required J 41712 Oil Pressure Sensor Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Page 3977 1. Apply sealant GM U.S. P/N 12346004, Canada P/N 10953480, or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. - Tighten the oil pressure sensor to 20 Nm (15 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Timing Chain and Sprockets Installation - Tools Required J 41665 Crankshaft Balancer and Sprocket Installer 1. Install the key into the crankshaft keyway, if previously removed. 2. Tap the key (1) into the keyway until both ends of the key bottom onto the crankshaft. 3. Install the crankshaft sprocket onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3982 4. Use the J 41665 in order to install the crankshaft sprocket. Install the sprocket onto the crankshaft until fully seated against the crankshaft flange. 5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position. Important: Properly locate the camshaft sprocket locating pin with the camshaft sprocket alignment hole. - The sprocket teeth and timing chain must mesh. - The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. Locate the camshaft sprocket alignment mark in the 6 o'clock position. 6. Install the camshaft sprocket and timing chain. 7. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3983 Notice: Refer to Fastener Notice in Service Precautions. 8. Install the camshaft sprocket bolts. - Tighten the camshaft sprocket bolts to 35 Nm (26 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine Front Cover Bolt ...................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3987 Timing Cover: Service and Repair Engine Front Cover Replacement - Tools Required J 41476 Front and Rear Cover Alignment (at crankshaft seal area) Removal Procedure 1. Remove the water pump. 2. Remove the crankshaft balancer. 3. Remove the oil pan-to-front cover bolts. 4. Remove the front cover bolts. 5. Remove the front cover and gasket. 6. Discard the front cover gasket. 7. Clean and inspect the engine front cover. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3988 Important: Do not reuse the crankshaft oil seal or front cover gasket. - Do not apply any type of sealant to the front cover gasket (unless specified). - The special tool in this procedure is used to properly center the front crankshaft front oil seal. All gasket surfaces should be free of oil or other foreign material during assembly. - The crankshaft front oil seal MUST be centered in relation to the crankshaft. - An improperly aligned front cover may cause premature front oil seal wear and/or engine oil leaks. 1. Apply a 5 mm (0.20 inch) bead of sealant GM U.S. P/N 12378190, or equivalent 20 mm (0.80 inch) long to the oil pan to engine block junction. 2. Install the front cover gasket and cover. 3. Install the front cover bolts until snug. Do not overtighten. 4. Install the oil pan-to-front cover bolts until snug. Do not over tighten. 5. Install J 41476 to the front cover. 6. Align the tapered legs of the J41476with the machined alignment surfaces on the front cover. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3989 7. Install the crankshaft balancer bolt until snug. Do not overtighten. 7.1. Tighten the oil pan to front cover bolts to 25 Nm (18 ft. lbs.). 7.2. Tighten the engine front cover bolts to 25 Nm (18 ft. lbs.). 8. Remove the J 41476. 9. Install a NEW crankshaft front oil seal. 10. Install the water pump. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Measure with the Key On Engine Off with the fuel pump commanded ON. Vin (V,T,U) Fuel Pressure (gasoline) ..................................................................................................................... ................................................................. 55-62 psi Vin (Z) Fuel Pressure (ethanol) ....................................................................................................................... ................................................................. 48-54 psi These specifications are taken from the Fuel System Diagnosis. For complete testing of fuel pressures and volume see Fuel System Diagnosis, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE CAUTION: ^ Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. ^ Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 1. Install the fuel pressure gauge to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gauge in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gauge. 7. Inspect for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3996 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST DESCRIPTION Steps 1-2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3997 Steps 3-7 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3998 Steps 8-13 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3999 Steps 14-18 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 4000 Steps 19-25 The numbers below refer to the step numbers on the diagnostic table. 2. This step verifies that the fuel pump is operating. 4. This step tests for an internal fuel leak. If the fuel pressure drops during this test, then an internal loss of pressure is indicated. 6. This step tests the fuel pressure regulator. The fuel pressure regulator is controlled by the engine vacuum. With the engine vacuum applied, the pressure should drop to the specified value. 9. This step inspects the fuel pressure regulator for a fuel leak from the vacuum port. If fuel leaks from the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator. 10. This step tests for a loss of fuel pressure between the fuel feed pipe shut-off adapter and the fuel pump. 11. This step tests for a leaking fuel injector or for a leaking fuel pressure regulator. If the fuel pressure remains constant during this test, the fuel injectors are not leaking fuel. 14. This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, there is a restriction in the fuel return pipe. 16. This step determines if the fuel pressure regulator or the fuel pump is the cause of the low fuel pressure. If the pressure rises above the specified value, the fuel pump is OK. 18. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Thoroughly inspect all fuel electrical circuits. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed ........................................................................................................................................... .............................................................. 500-700 rpm Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Restriction Indicator > Component Information > Description and Operation Air Cleaner Restriction Indicator: Description and Operation Air Cleaner Restriction Indicator The air cleaner restriction indicator is located on the air cleaner assembly between the air filter and the mass air flow (MAF) sensor. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 4016 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 4022 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement Seat Track: All Technical Service Bulletins Interior - Loose/Unwanted Seat Movement Bulletin No.: 05-08-50-012A Date: July 24, 2006 TECHNICAL Subject: Unwanted/Loose Seat Movement (Apply Adhesive and Install New Bolts in Seat Mounting Rails) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac ESV 1999-2007 Chevrolet Silverado Pickup Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Pickup Models (Classic) 2000-2006 GMC Yukon, Yukon XL 2003-2006 HUMMER H2 with Power Driver Front Seat Power Adjuster (RPO AG1) and/or Passenger Seat Power Adjuster (RPO AG2) Supercede: This bulletin is being revised to add model years and additional Warranty Information. Please discard Corporate Bulletin Number 05-08-50-012 (Section 08 - Body and Accessories). Condition Some customers may comment on unwanted seat movement in the front power bucket seat (driver or passenger) during fast acceleration or hard braking. A metal to metal clicking noise is often heard at seat "stops." Cause The threads of the two zinc nut retainers (one on each side of the seat adjuster) may creep over time, causing a loss of self-rolling screw clamp load and ultimately causes relative rail and vehicle seat motion. Correction Apply adhesive and install new bolts in seat mounting rails using the following procedure. 1. Remove the front seat and invert onto a flat surface covered with a clean, non-scratch material (soft cloth or similar). Refer to the applicable Seats sub-section in SI. Adjust so that the seat mounting rails are at 45 degrees. 2. Remove the upper M8 mounting bolt from one rail and discard. Leave the other bolt intact as this will hold the track in place while working. Wipe the bolt hole area with a clean rag. Important: Only use the adhesive provided in the repair kit. Do not substitute with other adhesives. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement > Page 4028 3. Take one of the adhesive sachets and carefully cut the flag tip off the notched end spout in line with the notch. 4. While holding the sachet vertical, slowly dribble the adhesive into the edge of the bolt hole as shown, ensuring that the adhesive flows into the joint between the seat rail and the zinc block. DO NOT pour the adhesive down the center of the hole. The object is to let the adhesive "wick" between the zinc block and the seat rail in order to bond the two pieces together. Important: If the bolt thread strips or the proper torque cannot be achieved, then the entire seat adjuster mechanism must be replaced. 5. Replace the previous bolt with a new M8 bolt (1) (included) and install using a "click torque wrench" preset to 9 N.m (79 lb in). 6. Remove the second M8 mounting bolt from the rail and discard. 7. Repeat steps 2 through 5 for the second bolt. 8. Repeat steps 2 through 6 for the opposite mounting rail. 9. Before installing the seat into the vehicle, verify that the seat will function correctly and does not make any unusual noises during forward and rearward travel motion. 10. Install the seat. Refer to the applicable Seats sub-section of SI. 11. While sitting in the seat, verify seat function and listen for any unusual noises. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement > Page 4029 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement > Page 4035 3. Take one of the adhesive sachets and carefully cut the flag tip off the notched end spout in line with the notch. 4. While holding the sachet vertical, slowly dribble the adhesive into the edge of the bolt hole as shown, ensuring that the adhesive flows into the joint between the seat rail and the zinc block. DO NOT pour the adhesive down the center of the hole. The object is to let the adhesive "wick" between the zinc block and the seat rail in order to bond the two pieces together. Important: If the bolt thread strips or the proper torque cannot be achieved, then the entire seat adjuster mechanism must be replaced. 5. Replace the previous bolt with a new M8 bolt (1) (included) and install using a "click torque wrench" preset to 9 N.m (79 lb in). 6. Remove the second M8 mounting bolt from the rail and discard. 7. Repeat steps 2 through 5 for the second bolt. 8. Repeat steps 2 through 6 for the opposite mounting rail. 9. Before installing the seat into the vehicle, verify that the seat will function correctly and does not make any unusual noises during forward and rearward travel motion. 10. Install the seat. Refer to the applicable Seats sub-section of SI. 11. While sitting in the seat, verify seat function and listen for any unusual noises. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement > Page 4036 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 4037 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake duct (2). 2. Disconnect the electrical connector from the mass air flow/intake air temperature (MAF/IAT) sensor. 3. Loosen the 4 fasteners (8) securing the air cleaner housing top cover (4). 4. Lift and rotate the top cover (4) of the air cleaner housing to gain access to the air filter element. 5. Lift out the air filter element (5). 6. Inspect the air filter element for dust, dirt, or water. Clean or replace the air filter element if required. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 4038 1. Install the air filter element (5) into the air cleaner housing. 2. Rotate and install the top cover (4) to the air cleaner housing (6). 3. Insert the fasteners (8) to secure the top cover. 4. Connect the MAF/IAT electrical connector. 5. Install the intake duct. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE CAUTION: ^ Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. ^ Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 1. Install the fuel pressure gauge to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gauge in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gauge. 7. Inspect for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 4044 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance Of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 2. Remove the engine sight shield. 3. Loosen the fuel filler cap in order to relieve the fuel tank vapor pressure. 4. Connect the J 34730-1A to the fuel pressure valve. 5. Install the bleed hose of the gauge into an approved container. 6. Open the valve on the gauge to bleed the system pressure. The fuel connections are now safe for servicing. 7. Drain any fuel remaining in the gauge into an approved container. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition System Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection Ignition Cable: Service and Repair Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: ^ Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. ^ Any signs of cracks or splits in the wires. ^ Inspect each boot for the following conditions: Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 4050 Ignition Cable: Service and Repair Spark Plug Wire Replacement REMOVAL PROCEDURE 1. Disconnect the spark plug wire at each spark plug. ^ Twist each spark plug 1/2 turn. ^ Pull only on the boot in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the ignition coil. ^ Twist each spark plug boot 1/2 turn. ^ Pull only on the boot in order to remove the wires from the ignition coil. SPARK PLUG WIRE LENGTH V8 Spark Plug Wire Length V8 ^ The Melco(R), square design, uses a spark plug wire (1) that is 145 mm (5.70 in) length cable seal to cable seal. ^ The Delphi(R), round design uses a spark plug wire (2) that is 110 mm (4.30 in) length cable seal to cable seal. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 4051 Ignition Coils ^ There are 2 different manufacturers for the ignition coils, the Melco(R) (1) square design, and the Delphi(R) (2) round design. These 2 coils use 2 different spark plug wire, and mounting brackets. ^ Melco(R), square design, coil mounting bracket (1). ^ Delphi(R), round design, coil mounting bracket (2). INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 4052 1. Install the spark plug wires at the ignition coil. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: ^ Push sideways on each boot in order to inspect the seating. ^ Reinstall any loose boot. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - New Spark Plugs & Gapping Info. Spark Plug: Technical Service Bulletins Ignition System - New Spark Plugs & Gapping Info. INFORMATION Bulletin No.: 03-06-04-060B Date: July 30 2008 Subject: Information on New Spark Plugs and Gapping Models Attention: Please disregard the Set Gap Per Vehicle Specification statement on the side of an ACOelco(R) Iridium Spark Plug Box. The statement will be removed from the boxes in the future. Supercede: This bulletin is being revised to add the Chevrolet SSR and the 2005 Pontiac GTO. Please discard Corporate Bulletin Number 03-06-04-060A (Section 06 - Engine/Propulsion System). ^ A new spark plug has been released for use in the above vehicles. The new spark plug has an Iridium tip instead of the current Platinum tip. Due to the different tip design the gap of the spark plug has also changed. ^ The new spark plug P/N 12571164 with AC Delco P/N 41-985 is gapped to 1.01 mm (0.040 in) when the spark plug is made. Notice: The spark plug gap is set during manufacturing and should not be changed or damage to the spark plug may result. Any new spark plug found to not be properly gapped should not be used. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 4057 Spark Plug: Specifications This article has been updated with TSB #03-06-04-060B INFORMATION ON NEW SPARK PLUGS AND GAPPING SPARK PLUG GAP.............................................................................................................................. .................................................. 1.01 mm (0.040 in.) ^ A new spark plug has been released for use in the above vehicles. The new spark plug has an Iridium tip instead of the current Platinum tip. Due to the different tip design, the gap of the spark plug has also changed. ^ The new spark plug, P/N 12571164 with AC Delco P/N 41-985, is gapped to 1.01mm (0.040 inches) when the spark plug is made. Notice: The spark plug gap is set during manufacturing and should not be changed or damage to the spark plug may result. Any new spark plug found to not be properly gapped should not be used. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 4058 Spark Plug: Application and ID AC Plug Type ...................................................................................................................................... ................................................................... 25171803 NGK Plug Type .................................................................................................................................... ................................................................. 12567759 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection Spark Plug: Service and Repair Spark Plug Inspection SPARK PLUG USAGE ^ Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. ^ Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION ^ Inspect the terminal P05 (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. ^ Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 4061 ^ Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). ^ Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. ^ A rattling sound indicates internal damage. ^ A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. ^ Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION ^ Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. ^ Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures ^ Leaking fuel injectors ^ Excessive fuel pressure ^ Restricted air filter element ^ Incorrect combustion Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 4062 - Reduced ignition system voltage output ^ Weak coils ^ Worn ignition wires ^ Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. ^ Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 4063 Spark Plug: Service and Repair Spark Plug Replacement REMOVAL PROCEDURE 1. Remove the spark plug wires. 2. Loosen each spark plug 1 or 2 turns. 3. Brush or air blast away any dirt from around the spark plugs. 4. Remove the spark plugs 1 at a time. Place each plug in a tray marked with the corresponding cylinder numbers. INSTALLATION PROCEDURE 1. Properly position each spark plug washer. 2. Inspect each spark plug gap. Adjust each plug as needed. Specification Spark plug gap: 1.52 mm (0.060 in) NOTE: Refer to Fastener Notice in Service Precautions. 3. Hand start the spark plugs in the corresponding cylinders. 4. Tighten the spark plugs. Tighten ^ For used heads tighten the spark plugs to 15 N.m (11 lb ft). ^ For new aluminum heads tighten the spark plugs to 20 N.m (15 lb ft). ^ For new iron heads, tighten the spark plugs to 30 N.m (22 lb ft). 5. Install the spark plug wires. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1035 x 70% = 725) (150 x 70% = 105). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Engine Compression Test (Electronic Throttle) Compression Check: Testing and Inspection Engine Compression Test (Electronic Throttle) Engine Compression Test (Electronic Throttle) 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gauge at zero and crank the engine through four compression strokes, four puffs. 8. Check the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml. (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Recheck the compression and record the reading. 10. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1035 x 70% = 725) (150 x 70% = 105). Normal-Compression builds up quickly and evenly to the specified compression for each cylinder. - Piston Rings Leaking-Compression is low on the first stroke. Then compression builds up with the following strokes but does not reach normal. Compression improves considerably when you add oil. - Valves Leaking-Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. - If two adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Engine Compression Test (Electronic Throttle) > Page 4069 Compression Check: Testing and Inspection Engine Compression Test (Mechanical Throttle) Engine Compression Test (Mechanical Throttle) 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Block the throttle plate wide open. 6. Start with the compression gauge at zero and crank the engine through four compression strokes, four puffs. 7. Make the compression check for each cylinder. Record the reading. 8. If a cylinder has low compression, inject approximately 15 ml. (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Recheck the compression and record the reading. 9. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1035 x 70% = 725) (150 x 70% = 105). Normal-Compression builds up quickly and evenly to the specified compression for each cylinder. - Piston Rings Leaking-Compression is low on the first stroke. Compression then builds up with the following strokes but does not reach normal. Compression improves considerably when you add oil. - Valves Leaking-Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. - If two adjacent cylinders have lower than normal compression and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts (First Pass) ............................................................................................................ ...................................................... 15 Nm (11 ft. lbs.) Water Pump Bolts (Final Pass) ....................... .......................................................................................................................................... 30 Nm (22 ft. lbs.) Water Pump Cover Bolts ......................................................................................................... ................................................................. 15 Nm (11 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 4076 Water Pump: Service and Repair Water Pump Replacement (4.8L, 5.3L, and 6.0L Engines) Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Loosen the air cleaner outlet duct clamps at the following locations: - Throttle body - Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. If necessary, remove the engine sight shield. Refer to Engine Sight Shield Replacement (4.8L, 5.3L, and 6.OL (LQ4) or Engine Sight Shield Replacement (6.OL (LQ9) in Engine Mechanical - 4.8L, 5.3L, and 6.OL. 6. Remove the radiator vent inlet hose from the radiator hose clips. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 4077 7. Reposition the inlet hose clamp at the water pump. 8. Remove the inlet hose from the water pump. 9. Remove the fan blade. Refer to Fan Replacement. 10. Remove the accessory drive belt. Refer to Dive Belt Replacement - Accessory in Engine Mechanical - 4.8L, 5.3L, and 6.OL. 11. Reposition the outlet hose clamp at the water pump. 12. Remove the outlet hose from the water pump. 13. Reposition the surge tank outlet hose clamp at the water pump. 14. Remove the surge tank outlet hose from the water pump. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 4078 15. Reposition the heater inlet hose clamp at the water pump. 16. Remove the heater inlet hose from the water pump. 17. Remove the water pump bolts. 18. Remove the water pump and gaskets. 19. Discard the water pump gaskets. Installation Procedure Important: All gaskets surfaces are to be free of oil or other foreign material during assembly. 1. Install the water pump and NEW gaskets. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the water pump bolts. Tighten 2.1. Tighten the water pump bolts a first pass to 15 Nm (11 ft. lbs.). 2.2. Tighten the water pump bolts a final pass to 30 Nm (22 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 4079 3. Install the heater inlet hose to the water pump. 4. Position the heater inlet hose clamp at the water pump. 5. Install the surge tank outlet hose to the water pump. 6. Position the surge tank outlet hose clamp at the water pump. 7. Install the outlet hose to the water pump. 8. Position the outlet hose clamp at the water pump. 9. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory in Engine Mechanical - 4.8L, 5.3L, and 6.01L. 10. Install the fan blade. Refer to Fan Replacement. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 4080 11. Install the inlet hose to the water pump. 12. Position the inlet hose clamp at the water pump. 13. Install the engine vent inlet hose to the radiator hose clips. 14. If necessary, install the engine sight shield. Refer to Engine Sight Shield Replacement (4.8L, 5.3L, and 6.OL (LQ4) or Engine Sight Shield Replacement (6.OL (LQ9) in Engine Mechanical - 4.81L, 5.3L, and 6.0L. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. 15. Install the air cleaner outlet duct. 16. Install the radiator inlet hose clip to the outlet duct. 17. Tighten the air cleaner outlet duct clamps at the following locations: - Throttle body - MAF/IAT sensor - Tighten the air cleaner outlet duct clamp screws to 7 Nm (62 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 4081 18. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose > Component Information > Specifications Cooling System Air Bleeder Pipe / Hose: Specifications Engine Coolant Air Bleed Pipe and Cover Bolts ................................................................................................................................ 12 Nm (106 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose > Component Information > Service and Repair > Coolant Air Bleed Pipe Assembly Replacement Cooling System Air Bleeder Pipe / Hose: Service and Repair Coolant Air Bleed Pipe Assembly Replacement Coolant Air Bleed Pipe Assembly Replacement (4.8L, 5.3L, and 6.OL Engines) Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical - 4.8L, 5.31L, and 6.OL. 2. Remove the coolant air bleed pipe studs (1). 3. Remove the coolant air bleed pipe (2) with gaskets (3). 4. Remove the coolant air bleed pipe cover bolts (1) and covers (2). 5. Remove the gaskets from the coolant air bleed pipe and covers. 6. Discard the gaskets. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose > Component Information > Service and Repair > Coolant Air Bleed Pipe Assembly Replacement > Page 4088 7. Remove the coolant air bleed hose (1) from the pipe (2). Installation Procedure 1. Install the coolant air bleed hose (1) onto the pipe (2). Important: Install the gaskets properly onto the pipe and covers. Position the O-ring seal onto the nipple portion of the pipe. 2. Install the gaskets onto the coolant air bleed pipe and covers. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose > Component Information > Service and Repair > Coolant Air Bleed Pipe Assembly Replacement > Page 4089 3. Install the coolant air bleed pipe (2) and gaskets (3) onto the cylinder heads. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the coolant air bleed pipe studs (1). - Tighten the coolant air bleed pipe studs to 12 Nm (106 inch lbs.). 5. Install the coolant air bleed pipe covers (2) and bolts (1). - Tighten the coolant air bleed pipe cover bolts to 12 Nm (106 inch lbs.). 6. Install the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical - 4.81L, 5.31L, and 6.01L. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose > Component Information > Service and Repair > Coolant Air Bleed Pipe Assembly Replacement > Page 4090 Cooling System Air Bleeder Pipe / Hose: Service and Repair Coolant Air Bleed Hose Replacement Coolant Air Bleed Hose Replacement Removal Procedure 1. If necessary, remove the engine sight shield. Refer to Engine Sight Shield Replacement (4.8L, 5.3L, and 6.OL (LQ4) or Engine Sight Shield Replacement (6.OL (LQ9) in Engine Mechanical - 4.81L, 5.31L, and 6.01L. 2. Reposition the coolant air bleed hose clamp at the throttle body. 3. Remove the coolant air bleed hose from the throttle body. 4. Reposition the hose clamp at the pipe. 5. Remove the coolant air bleed hose (1) from the pipe (2). Installation Procedure 1. Install the coolant air bleed hose (1) to the pipe (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose > Component Information > Service and Repair > Coolant Air Bleed Pipe Assembly Replacement > Page 4091 2. Position the hose clamp at the pipe. 3. Install the coolant air bleed hose to the throttle body. 4. Position the coolant air bleed hose clamp at the throttle body. 5. If necessary, install the engine sight shield. Refer to Engine Sight Shield Replacement (4.8L, 5.3L, and 6.OL (LQ4) or Engine Sight Shield Replacement (6.OL (LQ9) in Engine Mechanical - 4.8L, 5.3L, and 6.OL. 6. Add engine coolant, if necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Air Bleeder Screw, Coolant > Component Information > Specifications Air Bleeder Screw: Specifications Coolant Air Bleed Pipe Stud/Bolt ..................................................................................................................................................... 12 Nm (106 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 4099 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 4100 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 4101 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 4102 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Add one liter if equipped with rear heating for all engines. Cooling System Capacity VORTEC 4800 V8 Automatic with Front A/C 14.4 qt (US) VORTEC 4800 V8 Automatic with Front and Rear A/C 15.8 qt (US) VORTEC 5300 V8 Automatic with Front A/C 14.4 qt (US) VORTEC 5300 V8 Automatic with Front and Rear A/C 15.8 qt (US) Vehicles equipped with optional air conditioner. VORTEC 6000 V8 Automatic 15.8 qt (US) VORTEC 6000 V8 Automatic with engine oil cooler 15.4 qt (US) Vehicles equipped with optional engine cooler VORTEC 8100 V8 Automatic 20.7 qt (US) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 4105 Coolant: Fluid Type Specifications Engine Coolant 50/50 mixture of clean, drinkable water and use only GM Goodwrench DEX-COOL or Havoline DEX-COOL Coolant. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Engine Block Coolant Drain Plugs ........................................................................................................................................................... 60 Nm (44 ft. lbs.) Cylinder Head Coolant Plug ................................................................................... .................................................................................. 20 Nm (15 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement Coolant Line/Hose: Service and Repair Radiator Vent Inlet Hose Replacement Radiator Vent Inlet Hose Replacement Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Reposition the vent inlet hose clamp from the radiator. 3. Remove the vent inlet hose from the radiator. 4. Reposition the vent inlet hose clamp from the surge tank. 5. Remove the vent inlet hose from the surge tank. Installation Procedure 1. Install the vent inlet hose to the surge tank. 2. Reposition the vent inlet hose clamp to the surge tank. 3. Install the vent inlet hose to the radiator. 4. Reposition the vent inlet hose clamp to the radiator. 5. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 4113 Coolant Line/Hose: Service and Repair Surge Tank Hose/Pipe Replacement - Inlet Surge Tank Hose/Pipe Replacement - Inlet Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Reposition the surge tank inlet hose clamp from the radiator. 3. Remove the surge tank inlet hose from the radiator. 4. Reposition the surge tank inlet hose clamp at the surge tank. 5. Remove the surge tank inlet hose (1) from the surge tank. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 4114 1. Install the surge tank inlet hose (1) to the surge tank. 2. Position the surge tank inlet hose clamp to the surge tank. 3. Install the surge tank inlet hose to the radiator. 4. Position the surge tank inlet hose clamp to the radiator. 5. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 4115 Coolant Line/Hose: Service and Repair Surge Tank Hose/Pipe Replacement - Outlet Surge Tank Hose/Pipe Replacement - Outlet (4.8L, 5.31-, and 6.0L Engines) - Tools Required J 43181 Heater Line Quick Connect Release Tool Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Loosen the air cleaner outlet duct clamps at the following locations: - Throttle body - Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the air cleaner outlet duct. 4. If equipped without regular production option (RPO) C36 auxiliary heater, remove the surge tank/heater outlet hose (1) from the mounting clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 4116 5. If equipped with RPO C36 auxiliary heater, remove the surge tank theater outlet hose (1) from the mounting clip. 6. Install the J 43181 to the surge tank outlet hose. 7. Close the J 43181 around the surge tank outlet hose. 8. Firmly pull the J 43181 into the quick connect end of the outlet hose. 9. If equipped without RPO C36 auxiliary heater, firmly grasp the outlet hose. Pull the outlet hose in order to disengage the hose from the heater and blower module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 4117 10. If equipped with RPO C36 auxiliary heater, firmly grasp the outlet hose. Pull the outlet hose in order to disengage the hose from the heater and blower module. 11. Reposition the surge tank outlet hose clamp at the surge tank. 12. Remove the surge tank outlet hose (2) from the surge tank. 13. Reposition the surge tank outlet hose clamp at the water pump. 14. Remove the surge tank outlet hose from the water pump. 15. Remove the surge tank outlet hose. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 4118 1. Install the surge tank outlet hose. 2. Install the surge tank outlet hose to the water pump. 3. Position the surge tank outlet hose clamp to the water pump. 4. Install the surge tank outlet hose (2) to the surge tank. 5. Position the surge tank outlet hose clamp to the surge tank. 6. If equipped with RPO C36 auxiliary heater, connect the surge tank outlet hose to the heater and blower module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 4119 7. If equipped without RPO C36 auxiliary heater, connect the surge tank outlet hose to the heater and blower module. Firmly push the hose onto the heater and blower module pipe until an audible click is heard. 8. If equipped with RPO C36 auxiliary heater, install the surge tank/heater outlet hose (1) to the mounting clip. 9. If equipped without RPO C36 auxiliary heater, install the surge tank/heater outlet hose (1) to the mounting clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Radiator Vent Inlet Hose Replacement > Page 4120 10. Install the air cleaner outlet duct. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. 11. Tighten the air cleaner outlet duct clamps at the following locations: - Throttle body - MAF/IAT sensor - Tighten the air cleaner outlet duct clamp screws to 7 Nm (62 inch lbs.). 12. Fill the cooling system, Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications Coolant Reservoir: Specifications Surge Tank Bolt/Nut ............................................................................................................................ ................................................... 9 Nm (80 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 4124 Coolant Reservoir: Service and Repair Surge Tank Replacement Removal Procedure 1, Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.81L, 5.31L, and 6.01L or Air Cleaner Assembly Replacement in Engine Controls - 8.1 L. 3. Remove the surge tank overflow hose from the surge tank. 4. Disconnect the low coolant level switch electrical connector (3). 5. Reposition the surge tank inlet hose clamp. 6. Remove the surge tank inlet (1) hose from the surge tank. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 4125 7. Reposition the surge tank outlet hose clamp. 8. Remove the surge tank outlet hose (2) from the surge tank. 9. Remove the bolt from the surge tank. 10. Remove the nut from the surge tank. 11. Remove the surge tank. Installation Procedure 1. Install the surge tank. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolt to the surge tank. - Tighten the bolt to 9 Nm (80 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 4126 3. Install the nut to the surge tank. - Tighten the nut to 9 Nm (80 inch lbs.). 4. Install the surge tank outlet hose (2) to the surge tank. 5. Position the surge tank outlet hose clamp. 6. Install the surge tank inlet hose (1) to the surge tank. 7. Position the surge tank inlet hose clamp. 8. Connect the low coolant level switch electrical connector (3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 4127 9. Install the surge tank overflow hose. 10. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.8L, 5.3L, and 6.01L or Air Cleaner Assembly Replacement in Engine Controls - 8.1 L. 11. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair Fan Replacement - Tools Required J 41240 Fan Clutch Remover and Installer - J 41240-5A Fan Clutch Wrench Removal Procedure 1. Remove the upper fan shroud. Refer to Fan Shroud Replacement - Upper (WIO M74) or Fan Shroud Replacement Upper (WIM74). 2. Install the J 41240 to the fan clutch. 3. Remove the fan blade. 4. Lay the fan blade face down on a workbench. 5. Remove the fan clutch bolts from the rear of the fan blade, if necessary. 6. Separate the fan clutch from the fan blade. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair > Page 4132 Installation Procedure Caution: Do not use or attempt to repair a damaged cooling fan assembly. Replace damaged fans with new assemblies. An unbalanced cooling fan could fly apart causing personal Injury and property damage. 1. Install the fan clutch bolts. 2. Install the fan clutch onto the fan blade, if necessary. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the fan clutch bolts. - Tighten the bolts to 23 Nm (17 ft. lbs.). 4. Install the fan blade. 5. Install the J 41240 to the fan clutch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair > Page 4133 - Tighten the fan clutch nut to 56 Nm (41 ft. lbs.). 6. Install the upper fan shroud. Refer to Fan Shroud Replacement - Upper (WIO M74) or Fan Shroud Replacement - Upper (WIM74). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > A/T - Intermittent Downshift/Slip/Cycling Diagnosis Fan Clutch: Technical Service Bulletins A/T - Intermittent Downshift/Slip/Cycling Diagnosis File In Section: 07 Transmission/Transaxle Bulletin No.: 99-07-30-016B Date: October, 2002 INFORMATION Subject: Diagnostic Information For Intermittent Transmission Downshift, Slip, Busy/cycling TCC or Noisy Cooling Fan Models: 1999-2000 Cadillac Escalade 2002-2003 Cadillac Escalade, Escalade EXT 1988-2003 Chevrolet Astro, Blazer, S-10, Silverado, Suburban 1989-2003 Chevrolet/Geo Tracker 1995-2003 Chevrolet Tahoe 1996-2003 Chevrolet Express 1988-1994 GMC S-15 1988-1999 GMC Suburban 1988-2003 GMC Safari, Sierra 1995-2003 GMC Sonoma, Yukon, Yukon XL 1996-2003 GMC Savana 1999-2001 GMC Envoy 1991-2001 Oldsmobile Bravada 2003 HUMMER H2 with Air Conditioning This bulletin is being revised to change the Model information and text. Please discard Corporate Bulletin Number 99-07-30-016A (Section 07 - Transmission/Transaxle) Some customers may comment that at times the transmission seems to slip, or that there is a loud roar from the engine with slow acceleration. This condition is most noticeable after the vehicle has sat idle for 12 or more hours, or on hot days when the A/C is on and the vehicle moves slowly with traffic. Typical comments from customers may include the following conditions: ^ Intermittent slipping ^ Intermittent downshift followed by an upshift, both with no apparent reason ^ Busyness or cycling of the TCC (torque converter clutch) at steady throttle conditions and on a level roadway ^ Noisy cooling fan The type of concern described above requires further definition. The customer should be asked the following questions: ^ Is the situation more pronounced with higher vehicle loads such as when pulling a trailer? ^ Do warmer ambient temperatures make the situation more pronounced? ^ When the condition occurred, did you have the A/C on, and were you driving in stop and go city traffic? ^ Does the condition exhibit itself on the first start-up after sitting more than eight hours? If the customer indicates that these conditions apply, and your observation confirms that the vehicle is operating properly, provide the customer with the vehicle operating description included at the end of this bulletin. Further action may not be necessary. A service procedure follows if further definition is required. Diagnostic Aids Cooling fan operation or the resulting sound varies. The cooling fan clutch may be described as a continuously variable clutch. If the vehicle engine is running, the fan blade is always turning unless the fan clutch is non-functional. The speed of the fan in relation to engine speed is temperature dependent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > A/T - Intermittent Downshift/Slip/Cycling Diagnosis > Page 4138 Maximum fan speed (air flow and related fan noise) through the engine compartment is experienced under two conditions. 1. When the vehicle sits in an unused condition for several hours, the viscous fluid within the thermostatic fan clutch assembly migrates and fully engages the clutch of the fan. After a short drive, the viscous fluid will migrate to the storage area in the fan clutch and the fan clutch will slip, reducing the noise (roar of the fan). This is normal thermostatic fan clutch operation. 2. When the engine is running, and the air being drawn by the fan or pushed through the radiator from the vehicle movement reaches a high enough temperature, the fan clutch will fully engage the fan clutch, drawing additional air through the radiator to lower the engine coolant temperature and A/C refrigerant temperature. When the cooling fan clutch fully engages, fan noise increases (for example; this is the same as switching an electric household fan from low to high speed). Some customers have interpreted this sound increase to be an increase in the engine RPM due to transmission downshift, transmission slipping, or TCC cycling. As the engine coolant temperature decreases, the fan clutch will begin to slip, lowering the actual speed of the fan blade and the resultant sound. Service Procedure When diagnosing an intermittent transmission downshift, slip, or busy/cycling TCC, follow these steps: 1. Verify the transmission fluid level and the fluid condition. Refer to the Automatic Transmission sub-section of the appropriate Service Manual. 2. Test drive the vehicle under the conditions described by the customer (ambient temperature, engine coolant temperature, trailering, etc.). It may be necessary to partially restrict airflow to the radiator in order to raise the engine coolant temperature to match the customer's conditions. 3. Monitor the engine RPM and the engine coolant temperature using a scan tool. 4. Listen for an actual increase in the engine RPM. Use either the vehicle tachometer (if equipped), the Tech 2 RPM or transmission slip speed as an indicator, rather than just the sound. If the engine RPM display on the tachometer or the Tech 2 increases, verify the scan tool RPM and coolant temperature readings. If the noise increase is due to the engagement of the fan, the engine RPM will not increase and the engine coolant temperature will begin to decrease after the fan engages. As the fan runs, the engine coolant temperature will drop and the fan will disengage, reducing noise levels. The engine RPM will not decrease. This cycle will repeat as the engine coolant temperature rises again. If the above procedure shows the condition to be cooling fan-related, no further action is necessary. The vehicle should be returned to the customer and the condition explained. If the above procedure shows the condition to be other than cooling fan-related, refer to the Automatic Transmission sub-section of the appropriate Service Manual for transmission diagnosis information. The following information regarding the operation of the engine cooling fan should be photocopied and given to the customer. Intermittent Transmission Downshift All light duty trucks are equipped with a thermostatic engine cooling fan. This fan is designed to provide greater fuel efficiency and quieter operation than a standard fan. These benefits are possible through the addition of a thermostatic clutch to the fan drive. When the engine is cool (it the engine has been run in the last few hours), the clutch allows the fan to "slip" or turn at a speed slower than the engine. By turning at a slower speed, the fan uses less horsepower, which saves fuel, and is quieter. When the engine temperature reaches a preset temperature or if the engine has not been run for several hours, the fan "engages" and turns at the same speed as the engine. "Engagement" of the fan provides increased airflow through the radiator to cool the engine. As the airflow increases, fan operation becomes clearly audible. This increase in noise can easily be mistaken for an increase in engine RPM and may be incorrectly blamed on the automatic transmission. When operating an unloaded vehicle in cooler ambient temperatures, the thermostatic clutch usually won't fully engage. However, if the vehicle is pulling a trailer, is heavily loaded or is operated at high ambient temperatures, the thermostatic fan clutch may cycle on and off as the engine coolant temperature rises and falls. The sound of fan operation under the conditions described above is a sign that the cooling system on your vehicle is working correctly. Replacement or modification of the cooling system or the transmission parts will not change or reduce the noise level. Attempts to reduce this noise may cause you, the customer, to believe that your vehicle is not reliable and will inconvenience you by causing your vehicle to be out of service. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > A/T - Intermittent Downshift/Slip/Cycling Diagnosis > Page 4139 DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 4140 Fan Clutch: Specifications Fan Clutch Bolt .................................................................................................................................... ..................................................... 23 Nm (17 ft. lbs.) Fan Clutch Nut ................................................. ......................................................................................................................................... 56 Nm (41 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 4141 Fan Clutch: Service and Repair Fan Clutch Replacement - Tools Required J 41240 Fan Clutch Remover and Installer - J 41240-5A Fan Clutch Wrench Removal Procedure 1. Remove the upper fan shroud. Refer to Fan Shroud Replacement - Upper (IMIO M74) or Fan Shroud Replacement Upper (WIM74). 2. Install the J 41240 to the fan clutch. 3. Remove the fan blade. 4. Lay the fan blade face down on a workbench. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 4142 5. Remove the fan clutch bolts from the rear of the fan blade. 6. Separate the fan clutch from the fan blade. Installation Procedure 1. Install the fan clutch bolts. 2. Install the fan clutch onto the fan blade. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the fan clutch bolts. - Tighten the bolts to 23 Nm (17 ft. lbs.). 4. Install the fan blade. 5. Install the J 41240 to the fan clutch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 4143 - Tighten the fan clutch nut to 56 Nm (41 ft. lbs.). 6. Install the upper fan shroud. Refer to Fan Shroud Replacement - Upper (W10 M74) or Fan Shroud Replacement - Upper (WIM74). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4148 Engine Coolant Temperature (ECT) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4149 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.. 3. Drain the cooling system below the level of the ECT sensor. Refer to Draining and Filling Cooling System in Cooling System. 4. Lower the vehicle. 5. Disconnect the electrical connector from the engine coolant temperature (ECT) sensor. 6. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: ^ Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. ^ Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4150 1. Coat the ECT sensor threads with sealer GM P/N 12346004 or the equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications Fan Shroud: Specifications Fan Shroud Bolt ................................................................................................................................... ................................................... 9 Nm (80 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper Fan Shroud: Service and Repair Fan Shroud - Upper W/RPO M74 Fan Shroud Replacement - Upper (W/M74) Removal Procedure 1. Loosen the air cleaner outlet duct clamps from the throttle body. 2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor. 3. Remove the air cleaner outlet duct. 4. Remove the A/C line retainer from the fan shroud. 5. Remove the engine harness clip from the PCM cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 4156 6. Remove the TCM cover bolts. 7. Remove TCM cover from the fan shroud. 8. Loosen the TCM electrical connector bolts. 9. Disconnect the TCM electrical connectors (1). 10. Remove the TCM and cover. 11. Remove the fan shroud retainers. 12. Remove the fan shroud bolts 13. Remove the upper fan shroud. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 4157 1. Install the upper fan shroud. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the fan shroud bolts. - Tighten the bolts to 9 Nm (80 inch lbs.). 3. Install the fan shroud retainers. 4. Connect the TCM electrical connectors (1). 5. Install the TCM and cover. 6. Tighten the TCM electrical connector bolts. - Tighten - Tighten the bolts to 8 Nm (71 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 4158 7. Install the TCM cover to the fan shroud. 8. Install the TCM cover bolts. - Tighten the to 9 Nm (80 inch lbs.). 9. Install the engine harness clip to the PCM cover. 10. Install the A/C line retainer to the fan shroud. 11. Install the air cleaner outlet duct. 12. Tighten the air cleaner outlet duct clamp at the throttle body. - Tighten the clamp screws to 7 Nm (62 inch lbs.). 13. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. - Tighten the clamp screws to 7 Nm (62 inch lbs.). W/O RPO M74 Fan Shroud Replacement - Upper (W/O M74) Removal Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 4159 1. Loosen the air cleaner outlet duct clamps from the throttle body. 2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor. 3. Remove the air cleaner outlet duct. 4. Remove the throttle body heater hose retainer from the fan shroud. 5. Remove the inlet radiator hose retainer from the fan shroud. 6. Remove the fan shroud retainers. 7. Remove the fan shroud bolts 8. Remove the upper fan shroud. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 4160 1. Install the upper fan shroud. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the fan shroud bolts. - Tighten the bolts to 9 Nm (80 inch lbs.). 3. Install the fan shroud retainers. 4. Install the inlet radiator hose retainer to the fan shroud 5. Install the throttle body heater hose retainer to the fan shroud. 6. Install the air cleaner outlet duct. 7. Tighten the air cleaner outlet duct clamp at the throttle body. - Tighten the clamp screw to 7 Nm (62 inch lbs.). 8. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 4161 - Tighten the clamp screw to 7 Nm (62 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 4162 Fan Shroud: Service and Repair Fan Shroud - Lower Fan Shroud Replacement - Lower Removal Procedure 1. Remove the cooling fan. Refer to Fan Replacement. 2. If equipped with engine oil cooler, remove the oil cooler hose clip from the lower fan shroud. 3. Lift the lower fan shroud up in order to disengage the fan shroud from the retaining clips on the radiator. Installation Procedure 1. Install the lower fan shroud to the retaining clips on the radiator and firmly push down. 2. If equipped with the engine oil cooler, Install the oil cooler hose clip to the lower fan shroud. 3. Install the cooling fan. Refer to Fan Replacement. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 4167 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 4168 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 4169 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement Heater Core: Service and Repair Heater Core Replacement REMOVAL PROCEDURE 1. Remove the heater/vent module. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 2. Remove the heater core cover screws. 3. Remove the heater core cover. 4. Remove the heater core. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 4172 1. Install the heater core. 2. Install the heater core cover. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install heater core cover screws. Tighten Tighten the screws to 1.6 Nm (14 lb in). 4. Install the heater/vent module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 4173 Heater Core: Service and Repair Heater Core Replacement - Auxiliary REMOVAL PROCEDURE 1. Remove the auxiliary HVAC module (4) from the vehicle. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 2. Remove the air temperature actuator (1) from the auxiliary HVAC module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 4174 3. Remove the heater core cover (1) from the auxiliary HVAC module. 4. Remove the heater core (1) from the auxiliary HVAC module. INSTALLATION PROCEDURE 1. Install the heater core (1) to the auxiliary HVAC module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 4175 2. Install the heater core cover (1) to the auxiliary HVAC module. 3. Install the air temperature actuator (1) to the auxiliary HVAC module. 4. Install the auxiliary HVAC module assembly (4) to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Heater Hose: Service and Repair Heater Pipe Replacement - Auxiliary REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the auxiliary heater pipes (1, 2) from the heater inlet and outlet tees (3, 4). 3. Loosen the right front wheelhouse to gain access to the clamp behind the wheelhouse. Refer to Wheelhouse Panel Replacement in Body Front End. 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Remove the auxiliary heater pipes (2, 3) from the auxiliary heater core. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 4180 6. Remove the heater/A/C tubes retaining nut (4) from the stud (1) at the frame (6). 7. Remove the auxiliary heater pipes (2) from the clamps (5). 8. Remove the auxiliary heater pipes from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary healer pipes to the vehicle. 2. Install the auxiliary heater pipes (2) to the clamps (5). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the heater/A/C tubes retaining nut (4)10 the stud (1) at the frame (6). Tighten Tighten the heater/A/C tubes retaining nut to 7 N.m (62 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 4181 4. Install the auxiliary heater pipes (2, 3) to the auxiliary heater core. 5. Lower the vehicle. Refer to Lifting and Jacking the Vehicle. 6. Install the right front wheelhouse. 7. Install the auxiliary heater pipes (1, 2)10 the heater inlet and outlet tees (3, 4). 8. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 4182 Heater Hose: Service and Repair Heater Hose Replacement - Inlet REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. 5. Pull the connection apart. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 4183 6. Remove the inlet heater hose from the water pump. 7. Remove the inlet heater hose. INSTALLATION PROCEDURE 1. Install the inlet heater hose. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 4184 2. Install the inlet heater hose to the water pump. 3. Connect the heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hoses to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 4185 Heater Hose: Service and Repair Heater Hose Replacement - Outlet REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. 5. Pull the connection apart. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 4186 6. Remove the outlet heater hose from the water pump. 7. Reposition the outlet heater hose clamp at the surge tank. 8. Remove the outlet heater hose from the surge tank. 9. Remove the outlet heater hose. INSTALLATION PROCEDURE 1. Install the outlet heater hose. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 4187 2. Install the outlet heater hose to the water pump. 3. Install the outlet heater hose to the surge tank. 4. Install the outlet heater hose clamp to the surge tank. 5. Connect the heater and surge tank hoses to the heater core. Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Install the heater and surge tank hoses to the mounting clip. 7. Install the air intake tube. 8. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 4188 Heater Hose: Service and Repair Heater and A/C Pipe Repair - Auxiliary TOOLS REQUIRED J 41425 A/C Line Repair Kit Do not service the rear A/C or heater lines as a complete unit. Service the rear A/C or heater lines as a sectional repair. You can obtain the various sections of line through GMSPO. Use the J 41425 when any of the following actions damage the rear A/C or heater lines: - Rub-through - Collision damage - Leakage in the system Minimum Tube Length Required Table IMPORTANT: When you section the rear A/C or heater lines, ensure that the correct minimum length remains in the straight part of the line on both sides of the splice. Follow the Straight Line Repair procedure in order to repair line damage in a straight section of line. Follow the Line Sectioning Repair procedure in order to repair any damage in a bend area. Do not repair the rear A/C or heater lines in a bend area, replace the lines. Maintaining the original line shape will prevent vibrations and rub-through. Straight Line Repair 1. Recover the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. 2. Drain the coolant, if repairing the heater lines. Refer to Draining and Filling Cooling System in Engine Cooling. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Locate the area that requires repair. 5. Obtain a length of replacement line to make the repair. 6. Use a tubing cutter in order to cut and remove the section of damaged line. IMPORTANT: The length of the replacement line must be the same as the section being replaced. 7. Use a tubing cutter in order to cut the replacement line to length. 8. Use the cleaning pad from the J41425 in order to clean any burrs or grease from the line ends. Be sure to clean at least 19 mm (0.75 in) from the line ends. 9. Use the LOK prep sealant in order to prep the line ends. 10. Apply one drop of the J 41425-3 sealing compound to the outside of each end of the line. 11. Insert the line ends into the LOK fitting. 12. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines. 13. Install the correct LOK fitting jaws into the J 41425-1 tool. 14. Install the J 41425-1 tool over the LOK connectors. Verify that the LOK connector ends are positioned in the counter bores of the jaws. IMPORTANT: Hold the J 41425-1 tool body with a 3/8" breaker bar. 15. Tighten the forcing screw of the J 41425-1 tool. When fully seated, the LOK connector collars will bottom out on the center shoulder of the LOK fitting. 16. Loosen the forcing screw and remove the J 41425-1 tool from the repaired line. 17. Repeat Step 8 through Step 16 to repair the other end of the line. 18. Verify that the LOK fittings are correctly installed. 19. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 4189 20. Refill the coolant, if drained. Refer to Draining and Filling Cooling System in Engine Cooling. 21. Evacuate and recharge the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. Line Sectioning Repair 1. Recover the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. 2. Drain the coolant, if repairing the heater lines. Refer to Draining and Filling Cooling System in Engine Cooling. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Obtain a new A/C or heater line for sectioning. IMPORTANT: Stagger the splices if repairing more than one line. 5. Scribe a mark on the line that will be sectioned. 6. Use a tubing cutter in order to cut the line or lines being replaced. 7. Remove the section of line being replaced from the vehicle. IMPORTANT: The length of the replacement line must be the same as the line being replaced. 8. Install the replacement line to the vehicle. 9. Use a tubing cutter in order to cut the replacement line to length. 10. Use the cleaning pad from the J 41425 in order to clean any burrs or grease. Be sure to clean at least 19 mm (0.75 in) from the A/C line. 11. Use the LOK prep sealant in order to prep the A/C or heater line. 12. Apply one drop of the J 41425-3 sealing compound to the outside of each line end. 13. Insert the line ends into the LOK fitting. 14. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines. 15. Install the correct LOK fitting jaws into the J41425-1 tool. 16. Install the J 41425-1 tool over the LOK connectors. Verify that the LOK connector ends are positioned in the counter bores of the jaws. 17. Hold the tool body with a 3/8" breaker bar. Turn the forcing screw until both of the connector collars bottom on the center shoulder of the LOK fitting. 18. Loosen the forcing screw. Remove the tool from the repaired line. 19. Verify that the LOK fitting is correctly installed. 20. Lower the vehicle. 21. Refill the coolant, if drained. Refer to Draining and Filling Cooling System in Engine Cooling. 22. Evacuate and recharge the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions Temperature Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4195 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4196 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4197 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4198 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4199 Temperature Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4200 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4201 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4202 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4203 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4204 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4205 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4206 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4207 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4208 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4209 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4210 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4211 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4212 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4213 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4214 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4215 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4216 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4217 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4218 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4219 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4220 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4221 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4222 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4223 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4224 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4225 Temperature Gauge: Electrical Diagrams For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Diagrams. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Page 4226 Temperature Gauge: Description and Operation ENGINE COOLANT TEMPERATURE GAGE The IPC displays the engine coolant temperature as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the engine coolant temperature. The engine coolant temperature gage defaults to 75°C (160°F) or below when: ^ The PCM detects a malfunction in the engine coolant temperature sensor circuit. ^ The IPC detects a loss of class 2 communication with the PCM. TRANSMISSION TEMPERATURE GAGE The IPC displays the transmission temperature as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the transmission temperature. The transmission temperature gage will default to 40°C (100°F) or below if: ^ The PCM detects a malfunction in the transmission temperature sensor circuit. ^ The IPC detects a loss of class 2 communications with the PCM. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Page 4227 Temperature Gauge: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Testing and Inspection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair Drain Cock Replacement Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Remove the radiator drain cock. Installation Procedure 1. Install the radiator drain cock. 2. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet Radiator Hose: Service and Repair Radiator Hose Replacement - Inlet Radiator Hose Replacement - Inlet Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Loosen the air cleaner outlet duct clamps at the following locations: - Throttle body - Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the air cleaner outlet duct. 4. If necessary, remove the engine sight shield. Refer to Engine Sight Shield Replacement (4.8L, 5.3L, and 6.OL (LQ4) or Engine Sight Shield Replacement (6.OL (L09) in Engine Mechanical - 4.8L, 5.3L, and 6.OL. 5. Remove the radiator vent inlet hose from the radiator inlet hose clips. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 4236 6. Reposition the inlet hose clamp from the radiator. 7. Remove the inlet hose from the radiator. 8. Remove the inlet hose clip from the fan shroud. 9. Reposition the inlet hose clamp from the water outlet. 10. Remove the inlet hose from the water outlet. Installation Procedure 1. Install the inlet hose to the water outlet. 2. Reposition the inlet hose clamp to the water outlet. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 4237 3. Install the inlet hose clip to the fan shroud. 4. Install the inlet hose to the radiator. 5. Reposition the inlet hose clamp to the radiator. 6. Install the radiator vent inlet hose to the radiator inlet hose clips. 7. If necessary, install the engine sight shield, Refer to Engine Sight Shield Replacement (4.8L, 5.3L, and 6.OL (LQ4) or Engine Sight Shield Replacement (6.OL (LQ9) in Engine Mechanical - 4.8L, 5.31L, and 6.OL. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. 8. Install the air cleaner outlet duct. 9. Tighten the air cleaner outlet duct clamps at the following locations: - Throttle body - MAF/IAT sensor - Tighten the air cleaner outlet duct clamp screws to 7 Nm (62 inch lbs.). 10. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 4238 Radiator Hose: Service and Repair Radiator Hose Replacement - Outlet Radiator Hose Replacement - Outlet (4.8L, 5.3L, and 6.OL Engines) Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Loosen the air cleaner outlet duct clamps at the following locations: - Throttle body - Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the air cleaner outlet duct. 4. Reposition the outlet hose clamp from the water pump. 5. Remove the outlet hose from the water pump. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 4239 6. Reposition the outlet hose clamp from the radiator. 7. Remove the outlet hose from the radiator. Installation Procedure 1. Install the outlet hose to the radiator. 2. Reposition the outlet hose clamp to the radiator. 3. Install the outlet hose to the water pump. 4. Reposition the outlet hose clamp to the water pump. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. 5. Install the air cleaner outlet duct. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 4240 6. Install the radiator inlet hose clip to the outlet duct. 7. Tighten the air cleaner outlet duct clamps at the following locations: - Throttle body - MAF/IAT sensor - Tighten the air cleaner outlet duct clamp screws to 7 Nm (62 inch lbs.). 8. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4246 Engine Coolant Temperature (ECT) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4247 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.. 3. Drain the cooling system below the level of the ECT sensor. Refer to Draining and Filling Cooling System in Cooling System. 4. Lower the vehicle. 5. Disconnect the electrical connector from the engine coolant temperature (ECT) sensor. 6. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: ^ Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. ^ Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4248 1. Coat the ECT sensor threads with sealer GM P/N 12346004 or the equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions Temperature Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4253 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4254 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4255 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4256 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4257 Temperature Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4258 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4259 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4260 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4261 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4262 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4263 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4264 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4265 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4266 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4267 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4268 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4269 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4270 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4271 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4272 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4273 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4274 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4275 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4276 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4277 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4278 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4279 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4280 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4281 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4282 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 4283 Temperature Gauge: Electrical Diagrams For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Diagrams. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Page 4284 Temperature Gauge: Description and Operation ENGINE COOLANT TEMPERATURE GAGE The IPC displays the engine coolant temperature as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the engine coolant temperature. The engine coolant temperature gage defaults to 75°C (160°F) or below when: ^ The PCM detects a malfunction in the engine coolant temperature sensor circuit. ^ The IPC detects a loss of class 2 communication with the PCM. TRANSMISSION TEMPERATURE GAGE The IPC displays the transmission temperature as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the transmission temperature. The transmission temperature gage will default to 40°C (100°F) or below if: ^ The PCM detects a malfunction in the transmission temperature sensor circuit. ^ The IPC detects a loss of class 2 communications with the PCM. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Page 4285 Temperature Gauge: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Testing and Inspection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Thermostat Housing Bolt ..................................................................................................................... ..................................................... 15 Nm (11 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications > Page 4289 Thermostat Housing: Service and Repair Thermostat Housing Replacement (4.8L, 5.3L, and 6.0L Engines) Removal Procedure Important: The thermostat is not serviceable separately. The water pump inlet and thermostat must be replaced as an assembly. 1. Remove the radiator outlet hose. Refer to Radiator Hose Replacement - Outlet (4.8L, 5.3L, and 6.OL Engines) or Radiator Hose Replacement Outlet (8.1L Engine). 2. Remove the water pump inlet bolts. 3. Remove the water pump inlet and thermostat from the water pump. Installation Procedure 1. Install the thermostat and water pump inlet to the water pump. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the water pump inlet bolts. - Tighten the water pump inlet bolts to 15 Nm (11 ft. lbs.). 3. Install the radiator outlet hose. Refer to Radiator Hose Replacement - Outlet (4.8L, 5.3L, and 6.OL Engines) or Radiator Hose Replacement Outlet (8.1L Engine). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts (First Pass) ............................................................................................................ ...................................................... 15 Nm (11 ft. lbs.) Water Pump Bolts (Final Pass) ....................... .......................................................................................................................................... 30 Nm (22 ft. lbs.) Water Pump Cover Bolts ......................................................................................................... ................................................................. 15 Nm (11 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 4293 Water Pump: Service and Repair Water Pump Replacement (4.8L, 5.3L, and 6.0L Engines) Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Loosen the air cleaner outlet duct clamps at the following locations: - Throttle body - Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. If necessary, remove the engine sight shield. Refer to Engine Sight Shield Replacement (4.8L, 5.3L, and 6.OL (LQ4) or Engine Sight Shield Replacement (6.OL (LQ9) in Engine Mechanical - 4.8L, 5.3L, and 6.OL. 6. Remove the radiator vent inlet hose from the radiator hose clips. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 4294 7. Reposition the inlet hose clamp at the water pump. 8. Remove the inlet hose from the water pump. 9. Remove the fan blade. Refer to Fan Replacement. 10. Remove the accessory drive belt. Refer to Dive Belt Replacement - Accessory in Engine Mechanical - 4.8L, 5.3L, and 6.OL. 11. Reposition the outlet hose clamp at the water pump. 12. Remove the outlet hose from the water pump. 13. Reposition the surge tank outlet hose clamp at the water pump. 14. Remove the surge tank outlet hose from the water pump. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 4295 15. Reposition the heater inlet hose clamp at the water pump. 16. Remove the heater inlet hose from the water pump. 17. Remove the water pump bolts. 18. Remove the water pump and gaskets. 19. Discard the water pump gaskets. Installation Procedure Important: All gaskets surfaces are to be free of oil or other foreign material during assembly. 1. Install the water pump and NEW gaskets. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the water pump bolts. Tighten 2.1. Tighten the water pump bolts a first pass to 15 Nm (11 ft. lbs.). 2.2. Tighten the water pump bolts a final pass to 30 Nm (22 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 4296 3. Install the heater inlet hose to the water pump. 4. Position the heater inlet hose clamp at the water pump. 5. Install the surge tank outlet hose to the water pump. 6. Position the surge tank outlet hose clamp at the water pump. 7. Install the outlet hose to the water pump. 8. Position the outlet hose clamp at the water pump. 9. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory in Engine Mechanical - 4.8L, 5.3L, and 6.01L. 10. Install the fan blade. Refer to Fan Replacement. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 4297 11. Install the inlet hose to the water pump. 12. Position the inlet hose clamp at the water pump. 13. Install the engine vent inlet hose to the radiator hose clips. 14. If necessary, install the engine sight shield. Refer to Engine Sight Shield Replacement (4.8L, 5.3L, and 6.OL (LQ4) or Engine Sight Shield Replacement (6.OL (LQ9) in Engine Mechanical - 4.81L, 5.3L, and 6.0L. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. 15. Install the air cleaner outlet duct. 16. Install the radiator inlet hose clip to the outlet duct. 17. Tighten the air cleaner outlet duct clamps at the following locations: - Throttle body - MAF/IAT sensor - Tighten the air cleaner outlet duct clamp screws to 7 Nm (62 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 4298 18. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair Catalytic Converter: Service and Repair Catalytic Converter Replacement (4.81- and 5.31- Engines) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the engine shield bolts and shield, if necessary. 3. Remove the oil pan skid plate bolts and plate, if necessary. 4. Unclip the oxygen sensor connection from the floor reinforcement. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Page 4303 5. Remove the clip from around the engine harness and the oxygen sensor pigtail. 6. Disconnect the connector position assurance (CPA) retainers. 7. Disconnect the oxygen sensor electrical connectors. 8. Unclip the oxygen sensors electrical connectors from the following: - Hose clip - Transmission crossmember 9. Disconnect the CPA retainers. 10. Disconnect the oxygen sensor electrical connectors (1, 2). 11. Remove the left exhaust manifold pipe nuts. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Page 4304 12. Remove the right exhaust manifold pipe nuts. 13. Remove the exhaust muffler nuts. 14. Remove the catalytic converter. 15. Remove the oxygen sensors if the catalytic converter is to be replaced. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Page 4305 Notice: Refer to Fastener Notice in Cautions and Notices. 1. If the catalytic converter was replaced, perform the following: 1.1. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors. 1.2. Install the oxygen sensors. - Tighten the oxygen sensors to 42 Nm (31 ft. lbs.). 2. Install the catalytic convertor. 3. Install NEW exhaust manifold pipe seals to the exhaust manifolds. 4. Install the right exhaust manifold pipe nuts until sung. 5. Install the left exhaust manifold pipe nuts until snug. 6. Tighten the right and left exhaust manifold pipe nuts. - Tighten the nuts to 50 Nm (39 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Page 4306 7. Install the exhaust muffler nuts. - Tighten the nuts to 40 Nm (30 ft. lbs.). 8. Connect the oxygen sensor electrical connectors (1, 2). 9. Connect the CPA retainers. 10. Clip the oxygen sensors electrical connectors to the following: - Hose clip - Transmission crossmember 11. Connect the oxygen sensor electrical connectors. 12. Connect the CPA retainers. 13. Install the clip around the engine harness and the oxygen sensor pigtail. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Page 4307 14. Clip the oxygen sensor connection to the floor reinforcement. 15. Install the oil pan skid plate and bolts, if necessary. - Tighten the bolts to 20 Nm (15 ft. lbs.) 16. Install the engine shield and bolts, if necessary. - Tighten the bolts to 20 Nm (15 ft. lbs.). 17. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Engine - New Exhaust Manifold Bolts/Torque Specs Exhaust Manifold: Technical Service Bulletins Engine - New Exhaust Manifold Bolts/Torque Specs Bulletin No.: 06-06-01-026 Date: December 22, 2006 INFORMATION Subject: L59, LR4, LM4, LM7, LQ4, LQ9, LS1, LS6 New Exhaust Manifold Bolts and Torque Specifications for GEN III Vortec(TM) Engine Models: 1999-2003 Cadillac Escalade 1999 Chevrolet Forward Control Chassis, P32 R/V Van Chassis, P42 Commercial Chassis 1998-2002 Chevrolet Camaro 1999-2003 Chevrolet Corvette, Express, Silverado, Suburban, Tahoe, W-Series Medium Duty Truck 1999 GMC Forward Control Chassis, P32 R/V Van Chassis, P42 Commercial Chassis 1999-2003 GMC Savana, Siera, Yukon, W-Series Medium Duty Truck 2003 GMC Siera Denali 1998-2002 Pontiac Firebird Formula, Firebird Trans Am 2003 HUMMER H2 1999-2003 Isuzu N-Series Medium Duty Truck with GEN III Vortec(TM) Engine (VINs V, G, P, S, T, N, U, Z, - RPOs 4.8L, 5.3L, 5.7L, 6.0L) A new exhaust manifold bolt and torque specification was introduced to the GEN III Vortec(TM) small block V8 engines beginning with the 2004 model year. When servicing any GEN III Vortec(TM) small bock exhaust manifolds, the exhaust manifold bolts should be replaced. - P/N 11518860 Exhaust Manifold Bolts Apply a 5 mm (0.2 in) wide bead of high temperature threadlocker to the threads of the exhaust manifold bolts before installing. - P/N 12345493 - GM High Temperature High Strength Threadlocker (U.S.) - P/N 10953488 - GM High Temperature High Strength Threadlocker (Canada) When tightening the exhaust manifold bolts it should be done with two passes. First tighten the two center bolts on the exhaust manifold. Then tighten the rest of the bolts, alternating from side to side, while working towards the outside bolts. Install the exhaust manifold bolts. Refer to the following torque sequence: Tighten Tighten to 10 N.m (89 lb in) on the first pass. Tighten to 20 N.m (15 lb ft) on the final pass. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Engine - New Exhaust Manifold Bolts/Torque Specs > Page 4312 Exhaust Manifold: Technical Service Bulletins Engine - Revised Exhaust Manifold Bolts/Torque Specs. Subject: L59, LR4, LM4, LM7, LQ4, LQ9, LS1, LS6 New Exhaust Manifold Bolts and Torque Specifications for GEN III Vortec Engine # 06-06-02-026 - (12/22/2006) Models A new exhaust manifold bolt and torque specification was introduced to the GEN III Vortec(TM) small block V8 engines beginning with the 2004 model year. When servicing any GEN III Vortec(TM) small block exhaust manifolds, the exhaust manifold bolts should be replaced. - P/N 11518860 Exhaust Manifold Bolts Apply a 5 mm (0.2 in) wide bead of high temperature threadlocker to the threads of the exhaust manifold bolts before installing. ^ P/N 12345493 - GM High Temperature High Strength Threadlocker (U.S.) ^ P/N 10953488 - GM High Temperature High Strength Threadlocker (Canada) Important: When tightening the exhaust manifold bolts it should he done with two passes. First tighten the two center bolts on the exhaust manifold. Then tighten the rest of the bolts alternating from side to side, while working towards the outside bolts. Install the exhaust manifold bolts. Refer to the following torque sequence: Tighten ^ Tighten to 10 Nm (89 lb in) on the first pass. ^ Tighten to 20 Nm (15 lb ft) on the final pass. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Page 4313 Exhaust Manifold: Specifications Exhaust Manifold Bolts (First Pass) .......................................................................................................................................... .................................................. 15 Nm (11 ft. lbs.) (Final Pass) ......................................................... .................................................................................................................................. 25 Nm (18 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left Exhaust Manifold Replacement - Left (4.8L, 5.3L, and 6.0L- Engines) Removal Procedure 1. Remove the ignition coils. 2. Remove the spark plugs. 3. Raise and suitably support the vehicle. 4. Remove the exhaust manifold pipe nuts. 5. Lower the vehicle. 6. Remove the exhaust manifold bolts, manifold, and gasket. 7. Discard the gasket. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 4316 8. Remove the heat shield bolts (3), and shield (2) from the exhaust manifold (1), if necessary. 9. Clean and inspect the exhaust manifold, if the manifold is not being replaced. Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices. 1. Install the heat shield (2), and bolts (3) to the exhaust manifold (1), if necessary. - Tighten the bolts to 9 Nm (80 inch lbs.). Important: - Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance. - The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. - Do not apply sealant to the first three threads of the bolt. 2. Apply a 5 mm (0.2 inch) wide band of threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts. 3. Install the exhaust manifold, NEW gasket and bolts. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 4317 3.1. Tighten the exhaust manifold bolts a first pass to 15 Nm (11 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. 3.2. Tighten the exhaust manifold bolts a final pass to 25 Nm (18 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. 4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head. 5. Raise the vehicle. 6. Install the exhaust manifold pipe nuts. - Tighten the nuts to 50 Nm (37 ft. lbs.). 7. Lower the vehicle. 8. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls -4.8L, 5.3L, and 6.OL. 9. Install the ignition coils. Refer to Ignition Coil(s) Replacement in Engine Controls - 4.8L, 5.3L, and 6.OL. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 4318 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Exhaust Manifold Replacement - Right (4.8L, 5.3L, and 6.01- Engines) 1. Remove the ignition coils. Refer to Ignition Coil(s) Replacement in Engine Controls - 4.8L, 5.3L, and 6.OL. 2. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 4.8L, 5.3L, and 6.OL. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 4. Remove the exhaust manifold pipe nuts. 5. Lower the vehicle. 6. If equipped, remove the bolts (1, 2, and 3) attaching the exhaust gas recirculation (EGR) valve pipe to the following: - Intake manifold - Cylinder head - Exhaust manifold 7. Remove the EGR valve pipe and gaskets, if equipped. With mild force, pull the EGR valve pipe from the intake manifold. 8. Remove the O-ring seal from the EGR valve pipe, if equipped. 9. Discard the gasket and the O-ring seal. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 4319 10. Remove the exhaust manifold bolts, manifold, and gasket. 11. Discard the gasket. 12. Remove the heat shield bolts (1), and shield (2) from the exhaust manifold (1), if necessary. 13. Clean and inspect the exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection in Engine Mechanical - 4.81L, 5.31L, and 6.01- Unit Repair. Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices. 1. Install the heat shield (2), and bolts (1) to the exhaust manifold (1), if necessary. - Tighten the bolts to 9 Nm (80 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 4320 Important: - Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance. - The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. - Do not apply sealant to the first three threads of the bolt. 2. Apply a 5 mm (0.2 inch) wide band of threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts. 3. Install the exhaust manifold, NEW gasket and bolts. 3.1. Tighten the exhaust manifold bolts a first pass to 15 Nm (11 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. 3.2. Tighten the exhaust manifold bolts a final pass to 25 Nm (18 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. 4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head. 5. Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the EGR valve pipe. 6. Install the EGR pipe. 7. Install the EGR valve pipe bolts until snug. 7.1. Tighten the intake manifold bolt (1) to 10 Nm (89 inch lbs.). 7.2. Tighten the cylinder head bolts (2) to 50 Nm (37 ft. lbs.). 7.3. Tighten the exhaust manifold bolts (3) to 30 Nm (22 ft. lbs.). 8. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 4.8L, 5.3L, and 6.OL. 9. Install the ignition coils. Refer to Ignition Coil(s) Replacement in Engine Controls - 4.8L, 5.3L, and 6.OL. 10. Raise the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 4321 11. Install the exhaust manifold pipe nuts. - Tighten the nuts to 50 Nm (37 ft. lbs.). 12. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Exhaust Manifold Pipe Nut .................................................................................................................. .................................................... 50 Nm (37 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Specifications Exhaust Pipe/Muffler Hanger: Specifications Exhaust Manifold Pipe Hanger Bracket Bolt ...................................................................................................................................... 12 Nm (106 inch lbs.) Exhaust Muffler Hanger Nut ................................................................................................. ................................................................... 50 Nm (39 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling Heat Shield: Customer Interest Exhaust System - Popping/Snapping Noise When Hot/Idling Bulletin No.: 03-06-05-008D Date: March 05, 2007 TECHNICAL Subject: Exhaust Popping/Snapping Noise When Vehicle is Hot, at Idle, or Immediately After Vehicle is Shut Off (Replace Muffler Heat Shield) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Suburban, Tahoe, Silverado, Silverado HD 2007 Chevrolet Silverado Classic, Silverado HD Classic 2002-2006 GMC Sierra, Sierra HD , Yukon, Yukon Denali, Yukon Denali XL 2007 GMC Sierra Classic, Sierra HD Classic 2003-2006 HUMMER H2 with 4.8L, 5.3L, 6.0L or 8.1L Gasoline Engine (VINs V, B, T, Z, N, V, G - RPOs LR4, L33, LM7, L59, LQ9, LQ4, L18) Supercede: This bulletin is being revised to add the 2006 and 2007 (Classic Only) model years and the 5.3L (L33) engine. Please discard Corporate Bulletin Number 03-06-05-008C (Section 06 Engine/Propulsion System). Condition Some customers may comment on a popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause As the exhaust system warms and cools, the muffler and the muffler heat shield expand and contract at different rates and may cause a popping and/or snapping noise. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. Correction Follow the service procedure below to correct this condition. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool. Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges could result in serious personal injury. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4336 Remove the nuts securing the muffler to the catalytic converter. On 6.0L and 8.1L equipped vehicles only, loosen the exhaust pipe clamp. Do not use oil base lubricants on the rubber exhaust hangers. Apply a soapy solution to the exhaust pipe hanger rods in order to ease the removal of the exhaust hangers. Pry the exhaust hangers free from the exhaust pipe hanger rods. It is not necessary to remove the muffler from the vehicle to replace the muffler heat shield. Reposition the muffler to gain access to the muffler heat shield. Use extreme caution not to damage the muffler when removing the heat shield from the muffler. Using an air-powered hack saw blade, or equivalent, cut off the existing muffler heat shield just as the heat shield rises off of the muffler. See the illustration above. Remove the heat shield from the muffler. Hammer flush the remaining heat shield to the muffler. The new heat shield should not come in contact with the remaining muffler heat shield. The new heat shield should not come in contact with the horizontal lock seam on the muffler. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4337 Install the new heat shield (see parts list below) onto the muffler as shown above. Install three straps, P/N 10391259, so that the strap screw head will be located on top of the muffler. Tighten Tighten the strap screw to 4 N.m (35 lb in). Cut off the excess strap material and bend the strap over the strap screw head as indicated above. Remove the exhaust pipe clamp. ONLY 6.0L and 8.1L equipped vehicles require a new exhaust pipe clamp, P/N 15103174. On 6.0L and 8.1L equipped vehicles only, install a new exhaust pipe clamp, P/N 15103174, on the exhaust pipe. Reposition the muffler in the correct position. Slide the muffler forward into position, aligning the studs with the rear of the catalytic converter. Install the nuts securing the muffler to the catalytic converter, but DO NOT tighten at this time. Apply a soapy solution to the following areas in order to ease the installation of the hangers. The inner diameter of the exhaust pipe hanger The exhaust pipe hanger rod Press the exhaust pipe hangers over the exhaust pipe hanger rods. Tighten Tighten the muffler nuts by hand until each contacts the metal flange. Tighten the muffler nuts to 45 N.m (33 lb ft). On 6.0L and 8.1L equipped vehicles only, tighten the exhaust clamp to 50 N.m (36 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4338 Lower the vehicle. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4339 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling Heat Shield: All Technical Service Bulletins Exhaust System - Popping/Snapping Noise When Hot/Idling Bulletin No.: 03-06-05-008D Date: March 05, 2007 TECHNICAL Subject: Exhaust Popping/Snapping Noise When Vehicle is Hot, at Idle, or Immediately After Vehicle is Shut Off (Replace Muffler Heat Shield) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Suburban, Tahoe, Silverado, Silverado HD 2007 Chevrolet Silverado Classic, Silverado HD Classic 2002-2006 GMC Sierra, Sierra HD , Yukon, Yukon Denali, Yukon Denali XL 2007 GMC Sierra Classic, Sierra HD Classic 2003-2006 HUMMER H2 with 4.8L, 5.3L, 6.0L or 8.1L Gasoline Engine (VINs V, B, T, Z, N, V, G - RPOs LR4, L33, LM7, L59, LQ9, LQ4, L18) Supercede: This bulletin is being revised to add the 2006 and 2007 (Classic Only) model years and the 5.3L (L33) engine. Please discard Corporate Bulletin Number 03-06-05-008C (Section 06 Engine/Propulsion System). Condition Some customers may comment on a popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause As the exhaust system warms and cools, the muffler and the muffler heat shield expand and contract at different rates and may cause a popping and/or snapping noise. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. Correction Follow the service procedure below to correct this condition. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool. Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges could result in serious personal injury. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4345 Remove the nuts securing the muffler to the catalytic converter. On 6.0L and 8.1L equipped vehicles only, loosen the exhaust pipe clamp. Do not use oil base lubricants on the rubber exhaust hangers. Apply a soapy solution to the exhaust pipe hanger rods in order to ease the removal of the exhaust hangers. Pry the exhaust hangers free from the exhaust pipe hanger rods. It is not necessary to remove the muffler from the vehicle to replace the muffler heat shield. Reposition the muffler to gain access to the muffler heat shield. Use extreme caution not to damage the muffler when removing the heat shield from the muffler. Using an air-powered hack saw blade, or equivalent, cut off the existing muffler heat shield just as the heat shield rises off of the muffler. See the illustration above. Remove the heat shield from the muffler. Hammer flush the remaining heat shield to the muffler. The new heat shield should not come in contact with the remaining muffler heat shield. The new heat shield should not come in contact with the horizontal lock seam on the muffler. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4346 Install the new heat shield (see parts list below) onto the muffler as shown above. Install three straps, P/N 10391259, so that the strap screw head will be located on top of the muffler. Tighten Tighten the strap screw to 4 N.m (35 lb in). Cut off the excess strap material and bend the strap over the strap screw head as indicated above. Remove the exhaust pipe clamp. ONLY 6.0L and 8.1L equipped vehicles require a new exhaust pipe clamp, P/N 15103174. On 6.0L and 8.1L equipped vehicles only, install a new exhaust pipe clamp, P/N 15103174, on the exhaust pipe. Reposition the muffler in the correct position. Slide the muffler forward into position, aligning the studs with the rear of the catalytic converter. Install the nuts securing the muffler to the catalytic converter, but DO NOT tighten at this time. Apply a soapy solution to the following areas in order to ease the installation of the hangers. The inner diameter of the exhaust pipe hanger The exhaust pipe hanger rod Press the exhaust pipe hangers over the exhaust pipe hanger rods. Tighten Tighten the muffler nuts by hand until each contacts the metal flange. Tighten the muffler nuts to 45 N.m (33 lb ft). On 6.0L and 8.1L equipped vehicles only, tighten the exhaust clamp to 50 N.m (36 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4347 Lower the vehicle. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 03-06-05-008D > Mar > 07 > Exhaust System - Popping/Snapping Noise When Hot/Idling > Page 4348 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Page 4349 Heat Shield: Specifications Exhaust Heat Shield Bolt ..................................................................................................................... ................................................... 9 Nm (80 inch lbs.) Exhaust Heat Shield Nut (Body Panel) ................................................................................................................................................... 9 Nm (80 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Heat Shield Replacement Dash Panel Heat Shield: Service and Repair Exhaust Heat Shield Replacement Dash Panel Exhaust Heat Shield Replacement Dash Panel Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the engine shield bolts and shield, if necessary. 3. Remove the exhaust heat shield nuts. 4. Remove the exhaust heat shield (1, 3) from the dash panel studs. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Heat Shield Replacement Dash Panel > Page 4352 1. Install the exhaust heat shield (1, 3) to the dash panel studs. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the exhaust heat shield nuts. - Tighten the nuts to 9 Nm (80 inch lbs.). 3. Install the engine shield and bolts, it necessary. - Tighten the bolts to 20 Nm (15 ft. lbs.). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Heat Shield Replacement Dash Panel > Page 4353 Heat Shield: Service and Repair Floor Panel Heat Shield Replacement Floor Panel Heat Shield Replacement Removal Procedure 1. Remove the exhaust manifold pipe, if necessary. Refer to Exhaust Manifold Pipe Replacement (6.OL, and 8.1L Engines). 2. Remove the catalytic converter, if necessary. Refer to Catalytic Converter Replacement (4.8L and 5.3L Engines) or Catalytic Converter Replacement (6.OL and 8.1. Engines) 3. Remove the exhaust front heat shield nuts. 4. Remove the exhaust front heat shield from the studs. 5. If vehicle is a crew cab pick-up truck, remove the exhaust heat shield nuts. 6. Remove the exhaust heat shield(s) from the studs. 7. If vehicle is a sport utility vehicle, remove the exhaust heat shield nuts. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Heat Shield Replacement Dash Panel > Page 4354 8. Remove the exhaust heat shield from the studs. Installation Procedure 1. If vehicle is a sport utility vehicle, install the exhaust heat shield to the studs. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the exhaust heat shield nuts. - Tighten the nuts to 9 Nm (80 inch lbs.). 3. If the vehicle is a crew cab pick-up truck, install the exhaust heat shield(s) to the studs. 4. Install the exhaust heat shield nuts. - Tighten the nuts to 9 Nm (80 inch lbs.). 5. Install the exhaust front heat shield to the studs. 6. Install the exhaust front heat shield nuts, Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Heat Shield Replacement Dash Panel > Page 4355 - Tighten the nuts to 9 Nm (80 inch lbs.). 7. Install the catalytic converter, if necessary. Refer to Catalytic Converter Replacement (4.8L and 5.3L Engines) or Catalytic Converter Replacement (6.OL and 8.1L Engines). 8. Install the exhaust manifold pipe, if necessary. Refer to Exhaust Manifold Pipe Replacement (6.OL, and 8.1. Engines). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Heat Shield Replacement Dash Panel > Page 4356 Heat Shield: Service and Repair Exhaust Heat Shield Replacement Exhaust Heat Shield Replacement Removal Procedure 1. Remove the exhaust muffler. Refer to Muffler Replacement (4.8L and 5.3L Engines) or Muffler Replacement (6.OL and 8.1. Engines). 2. It equipped with a short bed, remove the exhaust heat shield bolts. 3. Remove the exhaust heat shield. Installation Procedure 1. If equipped with a short bed, install the exhaust heat shield. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the exhaust heat shield bolts. - Tighten the bolts to 9 Nm (80 inch lbs.). 3. Install the exhaust muffler. Refer to Muffler Replacement (4.8L and 5.3L Engines) or Muffler Replacement (6.OL and 8.1L Engines). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications Muffler: Specifications Exhaust Muffler Clamp Bolt ................................................................................................................. .................................................... 30 Nm (22 ft. lbs.) Exhaust Muffler Nut .......................................... ....................................................................................................................................... 40 Nm (30 ft. lbs.) Exhaust Pipe Clamp .................................................................................................................... .............................................................. 40 Nm (30 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 4360 Muffler: Service and Repair Muffler Replacement (4.81- and 5.31- Engines) - Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Remove the rear tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 2. Remove the oil pan skid plate bolts and plate, if necessary. 3. Remove the spare tire. 4. If servicing a vehicle equipped with regular production option (RPO) Z55, disconnect the chassis harness from the following electrical connectors: - Electronic suspension rear position sensor (1) - Rear shock (2) Important: Do not attempt to pry the rear suspension sensor link rod from the rear position sensor ball stud. 5. Remove the left and right sensor link rods from the sensors, perform the following: 5.1. Support the sensor lever with your hand 5.2. Twist the link rod in order to remove it from the ball stud 6. Install adjustable jack stands under the rear axle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 4361 7. Remove the rear axle vent hose from the rear axle, if necessary. 8. Remove the vent hose swivel clip from the rear brake crossover pipe. 9. Remove the rear shock absorbers lower bolts and nuts. 10. Lower the rear axle slightly, using the adjustable jack stands, in order to remove the muffler. 11. Remove the exhaust muffler nuts. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 4362 12. Remove the muffler from the insulators. Installation Procedure 1. Apply lubricant to the exhaust insulators in order to aid in installation. 2. Install the muffler to the insulators. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the exhaust muffler nuts. - Tighten the nuts to 40 Nm (30 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 4363 4. Raise the rear axle, using the adjustable jackstands. 5. Install the lower bolts and nuts to the rear shock absorbers. - Tighten the rear bolts to 95 Nm (70 ft. lbs.). 6. Remove the adjustable jack stands from under the rear axle. 7. Install the vent hose swivel clip to the rear brake crossover pipe. 8. Install the rear axle vent hose to the rear axle, if necessary. 9. If servicing a vehicle, equipped with RPO Z55, install the left and right sensor link rods to the sensors. Using J 38185 install the link rods to the ball studs on the sensor levers. 10. Connect the chassis harness to the following electrical connectors: - Electronic suspension rear position sensor (1) - Rear shock (2) 11. Install the spare tire. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 4364 12. Install the oil pan skid plate and bolts, if necessary. - Tighten the bolts to 20 Nm (15 ft. lbs.). 13. Install the rear tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Manifold Gasket > Component Information > Service and Repair Exhaust Manifold Gasket: Service and Repair Exhaust Seal Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the engine shield bolts and shield, if necessary. 3. Remove the oil pan skid plate bolts and plate, if necessary. 4. Disconnect the CPA retainer. 5. Disconnect the oxygen sensor electrical connector (1). 6. Support the catalytic converter or exhaust manifold pipe with adjustable jackstands. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Manifold Gasket > Component Information > Service and Repair > Page 4369 7. Remove the right exhaust manifold pipe nuts. 8. Remove the left exhaust manifold pipe nuts. 9. Remove the exhaust hanger mounting bracket bolts. 10. Lower the catalytic converter or exhaust manifold pipe using the adjustable jackstands. 11. Remove the exhaust manifold pipe seal(s). Installation Procedure 1. Install the exhaust manifold pipe seal(s). 2. Raise the catalytic converter or exhaust manifold pipe using the adjustable jackstands. 3. Install the exhaust hanger mounting bracket bolts. Notice: Refer to Fastener Notice in Cautions and Notices. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Manifold Gasket > Component Information > Service and Repair > Page 4370 4. Install the left exhaust manifold pipe nuts. - Tighten the transmission bolts to 100 Nm (74 ft. lbs.). - Tighten the exhaust pipe hanger bracket bolts to 12 Nm (106 inch lbs.). - Tighten the exhaust manifold pipe nuts to 50 Nm (39 ft. lbs.). 5. Install the right exhaust manifold pipe nuts. - Tighten the nuts to 50 Nm (39 ft. lbs.). 6. Connect the oxygen sensor electrical connector (1). 7. Connect the CPA retainer. 8. Remove the adjustable jackstands from catalytic converter or exhaust manifold pipe. 9. Install the oil pan skid plate and bolts, if necessary. - Tighten the bolts to 20 Nm (15 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Manifold Gasket > Component Information > Service and Repair > Page 4371 10. Install the engine shield and bolts, if necessary. - Tighten the bolts to 20 Nm (15 ft. lbs.). 11. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4380 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4381 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4382 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4383 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4384 Body Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4385 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4386 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4387 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4388 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4389 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4390 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4391 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4392 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4393 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4394 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4395 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4396 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4397 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4398 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4399 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4400 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4401 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4402 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4403 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4404 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4405 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4406 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4407 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4408 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4409 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4410 Body Control Module: Connector Views Body Control Module Connector (BCM) - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4411 Body Control Module (BCM) - C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4412 Body Control Module (BCM) - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4413 Body Control Module: Electrical Diagrams Controlled/Monitored Subsystem References Controlled/Monitored Subsystem References Body Control Module Schematics: Controlled/Monitored Subsystem References Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4414 Exterior Lighting Systems References Exterior Lighting Systems References Body Control Module Schematics: Exterior Lighting Systems References Interior Lighting Systems References Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4415 Interior Lighting Systems References Body Control Module Schematics: Interior Lighting Systems References Power, Ground and Serial Data Power, Ground and Serial Data Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4416 Body Control Module Schematics: Power, Ground And Serial Data Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures IMPORTANT: If any module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not properly configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: ^ The battery is fully charged. ^ The ignition switch is in the RUN position. ^ The DLC is accessible. ^ All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: ^ Inspect all BCM connections. ^ Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to the Theft Deterrent sub-system for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve History DTCs from all modules. 5. Clear all history DTCs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 4419 Body Control Module: Removal and Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable(s). 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the BCM from the sliding bracket. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 4420 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. 4. Install the knee bolster. 5. Connect the negative battery cable(s). 6. Reprogram the BCM. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations Electronic Throttle Control Module: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 4424 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 4425 Electronic Throttle Control Module: Diagrams Throttle Actuator Control (TAC) Module Connector C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 4426 Throttle Actuator Control (TAC) Module Connector C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 4427 Electronic Throttle Control Module: Description and Operation THROTTLE ACTUATOR CONTROL (TAC) MODULE Throttle Actuator Control (TAC) Module The TAC module is the control center for the electronic throttle system. The TAC module and the powertrain control module (PCM) communicate via a dedicated redundant serial data circuit. The TAC module and the PCM monitor the commanded throttle position and compare the commanded position to the actual throttle position. This is accomplished by monitoring the APP and the TP sensor. These 2 values must be within a calibrated value of each other. The TAC module also monitors each individual circuit of the TP sensor and the APP to verify proper operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 4428 Electronic Throttle Control Module: Service and Repair THROTTLE ACTUATOR CONTROL (TAC) MODULE REPLACEMENT REMOVAL PROCEDURE 1. Release the retainer tab from the left side of the throttle actuator control (TAC) module. 2. Slowly slide the TAC module out of the retaining bracket. 3. Disconnect the TAC module connectors from the TAC module. INSTALLATION PROCEDURE 1. Connect the TAC module connectors to the TAC module. 2. Slide the TAC module into the TAC module bracket. 3. Push the TAC module towards the bracket in order to snap the TAC module into the bracket. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 4437 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 4443 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 4448 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 4454 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4455 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4458 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4459 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4460 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4461 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4462 Engine Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4463 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4464 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4465 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4466 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4467 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4468 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4469 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4470 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4471 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4472 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4473 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4474 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4475 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4476 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4477 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4478 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4479 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4480 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4481 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4482 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4483 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4484 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4485 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4486 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4487 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4488 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4489 Powertrain Control Module (PCM) C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4490 Powertrain Control Module (PCM) C1 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4491 Powertrain Control Module (PCM) C2 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4492 Powertrain Control Module (PCM) C2 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4493 Powertrain Control Module (PCM) C2 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description Engine Control Module: Description and Operation Electronic Ignition (EI) System Description POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: ^ The Throttle Position (TP) Sensor ^ The Engine Coolant Temperature (ECT) Sensor ^ The Mass Airflow (MAF) sensor ^ The Intake Air Temperature (IAT) Sensor ^ The Vehicle Speed Sensor (VSS) ^ The transmission gear position or range information sensors ^ The Engine Knock Sensors (KS) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 4496 Engine Control Module: Description and Operation Powertrain Control Module (PCM) Description General Information The Powertrain Control Module (PCM) is designed to maintain exhaust emission levels while maintaining excellent driveability and fuel efficiency. The PCM controls the following operations: ^ The fuel control ^ The Ignition Control (IC) ^ The Knock Sensor (KS) system ^ The automatic transmission shift functions ^ The manual transmission ^ The cruise control enable, if equipped ^ The generator ^ The evaporative emissions (EVAP) purge ^ The A/C clutch control, if equipped ^ The secondary air injection (AIR), if equipped ^ The Exhaust Gas Recirculation (EGR) PCM Function The PCM supplies a buffered voltage to various sensors and switches. The PCM controls most components with electronic switches which complete a ground circuit when turned ON. Powertrain Control Module Powertrain Control Module The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is the control center of the vehicle. The PCM controls the following: ^ The fuel metering system ^ The transmission shifting ^ The ignition timing ^ The on-board diagnostics for powertrain functions The PCM constantly monitors the information from various sensors and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic functions for those systems. The PCM can recognize operational problems and alert the driver through the Malfunction Indicator Lamp (MIL) when a malfunction has occurred. When a malfunction is detected, the PCM stores a Diagnostic Trouble Code (DTC) which helps to identify problem areas. This is done to aid the technician in making repairs. The PCM supplies either 5.0 or 12.0 volts to power various sensors and switches. This is done through resistances in the PCM. The resistance is so high in value that a test lamp does not illuminate when connected to the circuit. In some cases, even an ordinary shop voltmeter does not give an accurate reading because the voltmeters resistance is too low. Therefore, a DMM with a minimum of 10 megaohms input impedance is required to ensure accurate voltage readings. The PCM controls output circuits such as the fuel injectors, the Idle Air Control (IAC), the cooling fan relays, etc. by controlling the ground or the power feed circuit through transistors or a device called an output driver module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 4497 Torque Management Torque management is a function of the PCM that reduces engine power under certain conditions. Torque management is performed for the following reasons: 1. To prevent over-stressing the powertrain and driveline components 2. To prevent damage to the vehicle during certain abusive maneuvers 3. To reduce engine speed when the IAC is out of the normal operating range The PCM monitors the following sensors and engine parameters in order to calculate engine output torque: ^ The air/fuel ratio ^ The Mass Air Flow (MAF) sensor ^ The Manifold Absolute Pressure (MAP) Sensor ^ The Intake Air Temperature (IAT) Sensor ^ The spark advance ^ The engine speed ^ The Engine Coolant Temperature (ECT) Sensor ^ The A/C clutch status The PCM monitors the torque converter status, the transmission gear ratio, and the engine speed in order to determine if torque reduction is required. The PCM retards the spark as appropriate to reduce engine torque output if torque reduction is required. The PCM also shuts OFF the fuel to certain injectors in order to reduce the engine power in the case of an abusive maneuver. The following are instances when engine power reduction is likely to be experienced: ^ During transmission upshifts and downshifts ^ During heavy acceleration from a standing start ^ When the clutch pedal is released too quick under a heavy load, 6.0L only ^ When one set of drive axles looses traction while the other set of drive axles are not moving, 4 Wheel Drive only and in 4WD low ^ If the IAC is out of the normal operating range, except 6.0L ^ When the driver is performing harsh or abusive maneuvers such as shifting into gear at high throttle angles or shifting the transmission from reverse to drive to create a rocking motion The driver is unlikely to notice the torque management actions in the first 2 instances. The engine power output is moderate at full throttle in the other cases. The PCM calculates the amount of spark retard necessary to reduce the engine power by the desired amount. The PCM disables the fuel injectors for cylinders 1, 4, 6, and 7 in the case of an abusive maneuver. Basic Knowledge Required Without a basic knowledge of electricity, you will have difficulty using the diagnostic procedures. You should understand the basic theory of electricity and know the meaning of voltage-volts, current-amps, and resistance-ohms. You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. PCM Service Precautions The PCM is designed to withstand normal current draws associated with vehicle operations. Avoid overloading any circuit. When testing for opens or shorts, do not ground any of the PCM circuits unless instructed. When testing for opens or shorts, do not apply voltage to any of the PCM circuits unless instructed. Only test these circuits with a DMM while the PCM connectors remain connected. Engine Controls Information The driveability and emissions information describes the function and operation of the powertrain control module (PCM). The engine controls Information contains the following: ^ Component locations ^ Wiring diagrams ^ PCM terminal end view and terminal definitions ^ Diagnostic System Check-Computers and Controls Systems ^ Diagnostic trouble code (DTC) tables The component system includes the following items: ^ Component and circuit description ^ On-vehicle service for each sub-system ^ Functional checks and diagnostic tables The DTCs also contain diagnostic support information containing circuit diagrams, circuit or system information, and helpful diagnostic information. System Status and Drive Cycle For Inspection/Maintenance The System Status selection is included in the scan tool System Info menu. Several states require that the I/M (OBD II system) pass on-board tests for the major diagnostics prior to having a vehicle emission inspection. This is Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 4498 also a requirement to renew license plates in some areas. Using a scan tool, the technician can observe the System Status, complete or not complete, in order to verify that the vehicle meets the criteria to comply with local area requirements. Using the System Status display, any of the following systems or combination of systems may be monitored for I/M Readiness: ^ The catalyst ^ The Evaporative Emission (EVAP) system ^ The Heated Oxygen Sensors (HO2S) ^ The HO2S heater ^ The Exhaust Gas Recirculation (EGR) system ^ The secondary air injection (AIR) system IMPORTANT: The System Status display indicates only whether or not the test has been completed. The System Status display does not necessarily mean that the test has passed. If a Failed Last Test indication is present for a DTC associated with one of the above systems, diagnosis and repair is necessary in order to meet the I/M requirement. Verify that the vehicle passes all of the diagnostic tests associated with the displayed System Status prior to returning the vehicle to the customer. Refer to the Typical Drive Cycle table, more than one drive cycle may be needed, to use as a guide to complete the I/M System Status tests. Typical Drive Cycle Following a DTC info clear, System Status clears for one or all of these systems. Following a battery disconnect or a PCM replacement, all System Status information clears. Primary System Based Diagnostics There are primary system-based diagnostics which evaluate the system operation and their effect on vehicle emissions. The primary system-based diagnostics are listed below, with a brief description of the diagnostic functionality. Oxygen Sensor Diagnosis Diagnose the fuel control heated oxygen sensors (HO2S) for the following conditions: ^ Heater performance, heater current monitor ^ Response switches, number or switches R/L or L/R ^ Response time, time to switch R/L or L/R ^ Inactive signal, output steady at bias voltage - approximately 450 mV ^ Signal fixed high ^ Signal fixed low Diagnose the catalyst monitor HO2S for the following functions: ^ Heater performance, heater current monitor ^ Signal fixed low ^ Signal fixed high ^ Inactive sensor Heated Oxygen Sensors The main function of the pre-catalyst HO2S is to provide the PCM with exhaust stream information in order to maintain proper fueling to hold emissions within acceptable levels. These oxygen sensors are always located between the exhaust manifold and the 3-way Catalytic Converter (TWC). After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases. The PCM uses the signal voltage from the fuel control HO2S in a Closed Loop in order to adjust the fuel injector pulse width. While in a Closed Loop, the PCM can adjust fuel delivery in order to maintain an air to fuel ratio which allows the best combination of emission control and driveability. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 4499 If the HO2S pigtail wiring, connector, or terminal are damaged, replace the entire HO2S assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must be provided with a clean air reference. This clean air reference is obtained by way of the HO2S wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference. Any attempt to repair the wires, connectors, or terminals could degrade HO2S performance. Catalyst Monitor Heated Oxygen Sensors In order to control emissions of HydroCarbons (HC), Carbon Monoxide (CO), and Oxides Of Nitrogen (NOx), the system uses a TWC. The catalyst promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting the HC and CO into harmless water vapor and carbon dioxide. The catalyst also converts NOx to nitrogen. Catalyst monitor HO2S, post-catalyst HO2S, are always located downstream of the catalytic converter. The PCM has the ability to monitor this process using the post catalyst HO2S. The pre-sensors produce an output signal which indicates the amount of oxygen present in the exhaust gas entering the TWC. The post sensor produces an output signal which indicates the oxygen storage capacity of the catalyst. This in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the pre-HO2S signal is far more active than that produced by the post-HO2S. In addition to catalyst monitoring, the post-HO2S has a limited role in controlling fuel delivery. If the post-HO2S signal indicates a high or low oxygen content for an extended period of time while in a Closed Loop, the PCM adjusts the fuel delivery slightly in order to compensate. Catalyst Monitor Diagnostic Operation The catalyst monitor diagnostic measures oxygen storage capacity of the catalyst converter. In order to do this, the HO2S are installed before and after the TWC. Voltage variations between the sensors allow the PCM to determine the catalyst emission performance. As a catalyst becomes less effective in promoting chemical reactions, the catalysts capacity to store and release oxygen generally degrades. The catalyst monitor diagnostic is based on a correlation between conversion efficiency and oxygen storage capacity. A good catalyst, e.g. 95 percent hydrocarbon conversion efficiency, shows a relatively flat output voltage on the post-catalyst HO2S. A degraded catalyst, 65 percent hydrocarbon conversion, shows a greatly increased activity in output voltage from the post catalyst HO2S. The post-catalyst HO2S is used to measure the oxygen storage and release capacity of the catalyst. A high oxygen storage capacity indicates a good catalyst. Low oxygen storage capacity indicates a failing catalyst. The TWC and the HO2S must be at operating temperature in order to achieve correct oxygen sensor voltages like those shown in the post-catalyst HO2S outputs graphic. The catalyst monitor diagnostic is sensitive to the following conditions: ^ Exhaust leaks ^ HO2S contamination ^ Alternative fuels Exhaust system leaks may cause the following: ^ Prevent a degraded catalyst from failing the diagnostic ^ Cause a false failure for a normally functioning catalyst ^ Prevent the diagnostic from running Some of the contaminants that may be encountered are phosphorus, lead, silica, and sulfur. The presence of these contaminants prevent the TWC diagnostic from functioning properly. Three-Way Catalyst Oxygen Storage Capacity Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 4500 Three-Way Catalyst Oxygen Storage Capacity The PCM must monitor the TWC system for efficiency. In order to accomplish this, the PCM monitors the pre-catalyst and post-catalyst HO2S. When the TWC is operating properly, the post-catalyst (2) HO2S shows significantly less activity than the pre-catalyst (1) HO2S. The TWC stores oxygen during the normal reduction and oxidation process. The TWC releases oxygen during the normal reduction and oxidation process. The PCM calculates the oxygen storage capacity using the difference between the pre-catalyst and post-catalyst HO2S voltage levels. Whenever the sensor activity of the post-catalyst (2) HO2S nears the sensor activity of the pre-catalyst (1) HO2S, the catalysts efficiency is degraded. Aftermarket HO2S characteristics may be different from the original equipment manufacturer sensor. This may lead to a false pass or a false fail of the catalyst monitor diagnostic. Similarly, if an aftermarket catalyst does not contain the same amount of precious metal content as the original part, the correlation between oxygen storage and conversion efficiency may be altered enough to set a false DTC. Misfire Monitor Diagnostic Operation The misfire monitor diagnostic is based on crankshaft rotational velocity, aka reference period, variations. The PCM determines crankshaft rotational velocity using the Crankshaft Position (CKP) Sensor and Camshaft Position (CMP) Sensor. When a cylinder misfires, the crankshaft slows down momentarily. By monitoring the crankshaft and CMP sensor signals, the PCM can calculate when a misfire occurs. For a non-catalyst damaging misfire, the diagnostic is required to monitor a misfire present for between 1,000-3,200 engine revolutions. For catalyst damage misfire, the diagnostic responds to the misfire within 200 engine revolutions Rough roads may cause false misfire detection. A rough road applies sudden torque variations to the drive wheels and drivetrain. This torque can intermittently decrease the crankshaft rotational velocity. The Antilock Braking (ABS) System detects uneven speed between the vehicles wheels and sends data via the serial data bus to the PCM to disable the misfire monitor until the rough road is no longer detected. On automatic transmission equipped vehicles, the Torque Converter Clutch (TCC) disables whenever a misfire is detected. Disabling the TCC isolates the engine from the rest of the drive line and minimizes the affect of the drive wheel inputs on crankshaft rotation. When the TCC has disabled as a result of misfire detection, the TCC is re-enabled after approximately 3,200 engine revolutions if no misfire is detected. The TCC remains disabled whenever the misfire is detected, with or without a DTC set. This allows the misfire diagnostic to reevaluate the system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 4501 Whenever a cylinder misfires, the misfire diagnostic counts the misfire and notes the crankshaft position at the time the misfire occurred. A current and a history misfire counter is maintained for each cylinder. The misfire current counters, Misfire Cur #1-8, indicate the number of firing events out of the last 200 cylinder firing events which were misfires. The misfire current counters displays real time data without a misfire DTC stored. The misfire history counters, Misfire Hist #1-8, indicate the total number of cylinder firing events which were misfires. The misfire history counters display 0 until the misfire diagnostic has failed and a DTC P0300 is set. Once the misfire DTC sets, the misfire history counters will be updated every 200 cylinder firing events. The Misfire counters graphic illustrates how these misfire counters are maintained. When crankshaft rotation is erratic, the PCM detects a misfire condition. Because of this erratic condition, the data that is collected by the diagnostic can sometimes incorrectly identify which cylinder is misfiring. The Misfire Counters graphic shows there are misfires counted from more than one cylinder. Cylinder #1 has the majority of counted misfires. In this case, the misfire counters would identify cylinder #1 as the misfiring cylinder. The misfires in the other counters were just background noise caused by the erratic rotation of the crankshaft. If the number of accumulated misfires is sufficient for the diagnostic to identify a true misfire, the diagnostic will set DTC P0300-Misfire Detected. The illustration depicts an accumulation in the history buffers. If two cylinders in sequential tiring order are both misfiring, the first misfiring cylinder will accumulate misfires in the cylinder buffer, but the second misfiring cylinder will not. This is because the PCM compares a misfiring cylinder with the cylinder 90 degrees prior to that cylinder in the firing order. Therefore the PCM would be comparing crankshaft speed of the second misfiring cylinder to an already suspect cylinder. The PCM however, will be able to detect both misfiring cylinders after the engine exceeds 2,000 RPM. This is because the PCM then starts to compare misfires to the opposing cylinder rather than the previous cylinder in the firing order. Use Techline equipment to monitor the misfire counter data on applicable vehicles. Knowing which specific cylinders misfire can lead to the root cause. Using the information in the misfire counters identifies which cylinders are misfiring. If the counters indicate cylinders number 1 and 4 misfired, look for a circuit or component common to both cylinders. The misfire diagnostic may indicate a fault due to a temporary fault not necessarily caused by a vehicle emission system malfunction. Examples include the following items: ^ Contaminated fuel Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 4502 ^ Running out of fuel ^ Fuel fouled spark plugs ^ Basic engine fault Fuel Trim System Operation The fuel trim system monitors the averages of short-term and long-term fuel trim values. If these fuel trim values stay at the individual limits for a calibrated period of time, a malfunction is indicated. The fuel trim diagnostic compares the average of short and long-term fuel trim values. If either value is within the thresholds, a pass is recorded. If either value is outside the thresholds, a rich or lean fuel trim DTC will set. Comprehensive Component Monitor Diagnostic Comprehensive component monitoring diagnostics are required to monitor emissions-related input and output powertrain components. Input Components The PCM monitors the input components for circuit continuity and out-of-range values. This includes performance checking. Performance checking refers to indicating a fault when the signal from a sensor does not seem reasonable, such as a Throttle Position (TP) sensor that indicates high throttle position at low engine loads or manifold Absolute Pressure (MAP) Voltage. The input components may include, but are not limited to, the following sensors: ^ The Vehicle Speed (VSS) Sensor ^ The Mass Air Flow (MAF) Sensor ^ The Intake Air Temperature (IAT) Sensor ^ The Crankshaft Position (CKP) Sensor ^ The Knock Sensor (KS) ^ The Throttle Position (TP) Sensor ^ The Engine Coolant Temperature (ECT) Sensor ^ The Camshaft Position (CMP) Sensor ^ The Manifold Absolute Pressure (MAP) Sensor In addition to the circuit continuity and rationality check, the engine coolant temperature (ECT) sensor is monitored for the sensors ability to achieve a steady state temperature to enable Closed Loop fuel control. Output Components Diagnose the output components for the proper response to PCM commands. Components where functional monitoring is not feasible will be monitored for circuit continuity and out-of-range values if applicable. Output components to be monitored include, but are not limited to, the following circuits: ^ The Idle Air Control (IAC) Motor ^ The Evaporative Emission (EVAP) System ^ The electronic transmission controls ^ The A/C relay, if equipped ^ The VSS output ^ The Malfunction Indicator Lamp (MIL) Control ^ The cruise control enable, if equipped Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) Engine Control Module: Service and Repair Powertrain Control Module (PCM) Programming (Off-board) BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: ^ DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. ^ The Off-Board Programming is used in situations where a control module must be programmed without having the vehicle present. The Off-Board Programming Adapter must be used to perform the Off-Board Programming procedure. The adapter allows the control module to power up and allows the Tech 2 to communicate with the control module. ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. Ensure that all connections are secure at the following locations: ^ The Off-Board Programming Adapter ^ The Tech 2 ^ The control module ^ The Techline terminal OFF-BOARD PROGRAMMING 1. Obtain the VIN of the vehicle for which the control module is being programmed. 2. With the Techline terminal, select Service Programming. 3. Select Tech 2, Reprogram ECU, and Off-Board Programming Adapter as the ECU location. 4. Connect the control module, Off-Board Programming Adapter, and the Tech 2 as described on the Techline terminal. Ensure you use the correct harness connector from the Off-Board Programming Adapter kit. 5. With the Tech 2, select Service Programming Request Information function. The Tech 2 communicates with the control module and receives the access code. 6. With the Tech 2, exit the Service Programming Request Information. 7. Disconnect the Tech 2 from the Off-Board Programming Adapter. 8. Connect the Tech 2 to the Techline terminal. 9. Turn ON the Tech 2. 10. With the Techline terminal, enter the VIN of the vehicle that will be receiving the control module. 11. The Techline terminal will display the message, attaching to database. 12. Identify what type of programming that you are performing. 13. Select the appropriate calibration file. 14. Ensure all connections are secure. 15. The Techline terminal displays a summary screen that summarizes your selections. After confirming you choices, the Techline terminal automatically loads the calibration files to the Tech 2. 16. After the download is complete, turn OFF the Tech 2. 17. Disconnect the Tech 2 from the Techline terminal. 18. Connect the Tech 2 to the Off-Board Programming Adapter. 19. With the Tech 2, select Service Programming. IMPORTANT: DO NOT turn OFF the Off-Board Programming Adapter if the programming procedure is interrupted or unsuccessful. Ensure the control module and the Off-Board Programming Adapter connections are secure and the Techline operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. 20. With the Tech 2, select Program. 21. After the download is complete, exit Service Programming. 22. Turn OFF the Off-Board Programming Adapter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 4505 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Programming (On-Board) BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customers concern. Ensure the following conditions are met before programming a control module: ^ Vehicle system voltage There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicle's battery. ^ Twilight sentinel ^ Interior lights ^ Daytime running lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. Refer to the Owners manual. ^ HVAC systems ^ Cooling System fans, etc. ^ The ignition is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. ^ All tool connections are secure. RS-232 - The connection at the DLC is secure. - Voltage supply circuits ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. REMOTE PROGRAMMING 1. Turn OFF the ignition. 2. Install the Tech 2 to the data link connector (DLC). 3. Turn ON the ignition, with the engine OFF. 4. Turn OFF all vehicle accessories. 5. With the Tech 2, select Service Programming. 6. Identify vehicle information as requested by the Tech 2. 7. Select the type of module you are programming. 8. Select the type of programming to be performed. 9. Verify the displayed VIN with the vehicle VIN. If the displayed VIN does not match the actual VIN, write down the actual VIN and correct the VIN at the Techline terminal. 10. When complete, Exit Service Programming. 11. Turn OFF the Tech 2 and disconnect the Tech 2 from the vehicle. 12. Turn OFF the ignition. 13. Connect the Tech 2 to the Techline terminal. 14. Select Service Programming. 15. Select Tech 2 as the tool you are using. 16. Select the type of programming to be performed. 17. Verify the displayed VIN with the vehicle VIN. Correct the VIN as necessary. 18. Select the type of module you are programming. 19. Identify what type of programming that you are performing. ^ Normal-This type of programming is for updating an existing calibration or programming a new controller. ^ Vehicle configuration index (VCI)-This selection is used if the vehicle VIN is unavailable or not recognized by the Techline terminal. Observe, you will need to contact the Techline Customer Support center to use this option. ^ Reconfigure-This is to reconfigure a vehicle, such as tire size and axle ratio changes. 20. Select the appropriate calibration file. 21. Ensure all connections are secure. 22. Select Reprog to initiate the download of the new calibration to the Tech 2. 23. After the download is complete, turn OFF the Tech 2. 24. Disconnect the Tech 2 from the Techline terminal. 25. Install the Tech 2 to the data link connector (DLC). 26. Turn ON the Tech 2. 27. Turn ON the ignition, with the engine OFF. 28. Select Service Programming. IMPORTANT: DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all the PCM and DLC Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 4506 connections are secure and the Techline(TM) operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. Refer to Powertrain Control Module (PCM) Replacement. 29. Select Program. 30. After the download is complete, EXIT Service Programming. 31. Turn OFF the ignition for 30 seconds. 32. Turn OFF the Tech 2. 33. If a control module is replaced the following service procedures must be performed: ^ CKP System Variation Learn Procedure ^ Inspection/Maintenance (I/M) Complete System Set Procedure ^ Programming Theft Deterrent System Components PROGRAMMING VERIFICATION 1. With a scan tool, clear the DTCs. 2. Attempt to start the engine. 3. Repeat the Service Programming procedure if the engine does not start or operates poorly. Perform the following procedures before programming the PCM: ^ Ensure the control module and DLC connections are OK. ^ Ensure the Techline operating software is up to date. ^ Ensure the calibration part number is correct for the vehicle. 4. Attempt to program the control module. If the control module still cannot be programmed properly, replace the control module. Refer to Powertrain Control Module (PCM) Replacement. You must program the replacement control module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 4507 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Replacement Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. ^ Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. ^ The replacement PCM must be programmed Removal Procedure 1. Release the PCM cover mounting holes (1,5) away from the mounting tabs on the PCM mounting bracket. 2. Release the PCM cover (8) from the mounting bracket. 3. Remove the PCM cover. NOTE: ^ Refer to PCM and ESD Notice in Service Precautions. ^ In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 4. Disconnect the PCM harness connectors (6). 5. Release the spring latch (2) from the PCM. 6. Release the PCM mounting tabs (3) from the PCM. 7. Remove the PCM (4) from the engine compartment. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 4508 1. Install the PCM (4) to the PCM mounting bracket (7) ensuring that the mounting tabs (3) are engaged. 2. Secure the spring latch (2) to the PCM. NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the PCM connectors (6) to the PCM (4). Tighten Tighten the PCM connector end fasteners to 8 N.m (71 lb in). 4. Install the PCM cover (8) to the PCM mounting bracket (7), ensuring the mounting tabs on the PCM mounting bracket are engaged into the mounting holes in the PCM cover. 5. If a new PCM is being installed, program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 4509 Engine Control Module: Service and Repair Service Programming System (SPS) The Service Programming System (SPS) allows a technician to program a control module through the Data Link Connector (DLC). The information transfer circuit that is used at the DLC is the same serial data circuit used by the scan tool for retrieving Diagnostic Trouble Codes (DTCs), displaying data, clearing DTCs, etc. This procedure offers the ability to install software/calibrations matched to a particular vehicle. Most control modules have 2 types of memory. The software/calibrations reside in the flash memory. The two types of memory are listed below: ^ Electrically Erasable Programmable Read Only Memory (EEPROM) This type of memory allows selected portions of memory to be programmed while other portions remain unchanged. Certain learned values reside in the EEPROM, such as: ^ The Vehicle Identification Number (VIN) ^ The crankshaft variation learned position ^ The software/calibrations identification numbers ^ The control module security information ^ Flash Read Only Memory - Flash Memory ^ Flash memory has increased memory storage capacity. During programming, all information within this type of memory is erased, and then replaced with entirely new information. Service Programming Methods The 4 methods of programming a control module and the proper tools for each method are as follows: ^ Remote Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle ^ Pass Thru Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle. ^ Off-Board Remote Programming, vehicle NOT available: The Tech 2 or other scan tool, Off-board Programming Adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle ^ Off-Board Pass Thru Programming - The Tech 2 or other scan tool, off-board programming adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle Before Programming A Control Module IMPORTANT: DO NOT program an existing control module with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A control module should only be programmed when the following occurs: ^ When a service procedure instructs you to replace the control module. The service part control module does not contain operating software or calibrations. ^ General Motors Corporation releases an updated software/calibration package. Ensure that the following conditions are met before programming a control module: ^ Vehicle system voltage: There are no charging system concerns. All charging system concerns must be repaired before programming a control module. - The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged before programming the control module. - A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or disable systems such as: ^ Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. ^ Heating, Ventilation, And Air Conditioning (HVAC) systems ^ Engine cooling fans, etc ^ The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. ^ All tool connections are secure: The RS-232 cable - The connection at the DLC - The voltage supply circuits Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 4510 - The OBPA ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. ^ If you are performing the pass-through programming procedure using a notebook computer without the power cord, ensure that the internal battery is fully charged. After Programming a Control Module The powertrain may operate slightly different after a control module software/calibration update. Operating the powertrain through various driving conditions allows the control module to re-learn certain values. The control module must re-learn the following after a software/calibration update: ^ Fuel trim correction ^ Idle Air Control (IAC) learned position ^ Automatic transmission shift adapts Other learned values only re-learn by performing a service procedure. If a control module is replaced the following service procedures may need to be performed: ^ The crankshaft variation learn procedure ^ The engine oil life reset procedure ^ The idle learn procedure ^ The inspection/maintenance complete system set procedure ^ The vehicle theft deterrent password learn procedure ^ The Throttle Position (TP) sensor learn procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay Fuel Pump Relay: Locations Fuel Pump Relay FUEL PUMP RELAY Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 4516 Locations View The Fuel Pump (FP) Relay is located in the Underhood Fuse Block. The Underhood Fuse Block is located at the left side of the engine compartment near the battery. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 4517 Fuel Pump Relay: Locations Fuel Pump Relay Secondary - With Dual Tanks SECONDARY FUEL PUMP RELAY (With Dual Tanks Only) Locations View The Secondary Fuel Pump (FP) Relay (1) is attached to the Underhood Fuse Block on bracket. The Underhood Fuse Block is located at the left side of the engine compartment near the battery. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 4518 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4521 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4522 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4523 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4524 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4525 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4526 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4527 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4528 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4529 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4530 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4531 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4532 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4533 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4534 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4535 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4536 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4537 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4538 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4539 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4540 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4541 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4542 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4543 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4544 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4545 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4546 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4547 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4548 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4549 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4550 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4551 Fuel Pump (FP) Relay-Secondary Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ignition Relay: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 4556 Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 4557 Ignition Relay: Testing and Inspection CIRCUIT DESCRIPTION The ignition relay supplies battery positive voltage to the following components: ^ The fuel injectors ^ The ignition coils ^ The powertrain control module (PCM) ^ The throttle actuator control (TAC) module DIAGNOSTIC AIDS The following will occur if the ignition relay fails to close: ^ The engine cranks, but does not run. ^ Scan tool data will be available. ^ Instrument panel lights will illuminate. TEST DESCRIPTION Steps 1-5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 4558 Steps 6-11 The numbers below refer to the step numbers on the diagnostic table. 2. This step is testing the battery positive voltage circuit of the ignition relay. 3. This step is testing the ignition 1 positive voltage circuit of the ignition relay. 4. This step is testing the coil ground circuit of the ignition relay. 5. This step isolates the circuits from the ignition relay. All of the circuits at the relay are good if the test lamp illuminates. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4564 Accelerator Pedal Position (APP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4565 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position (APP) Sensor The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 3 individual accelerator pedal position sensors within one housing. Three separate signal, low reference, and 5-volt reference circuits are used to connect the APP and the TAC module. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 1.0 volt at 0 pedal travel to above 2.0 volts at 100 percent pedal travel. APP sensor 2 voltage should decrease from above 4.0 volts at 0 pedal travel to below 2.9 volts at 100 percent pedal travel. APP sensor 3 voltage should decrease from above 3.8 volts at 0 percent pedal travel to below 3.1 volts at 100 percent pedal travel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4566 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the left instrument panel (IP) lower closeout insulator panel. 2. Disconnect the accelerator pedal position (APP) sensor harness connector. Remove the accelerator pedal mounting bolts. 3. Remove the APP assembly. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4567 1. Install the APP assembly to the steering column support bracket. NOTE: Refer to the Fastener Notice in Service Precautions. IMPORTANT: Always use a torque wrench in order to obtain the proper torque. 2. Install the accelerator pedal mounting bolts. Tighten Tighten the accelerator pedal mounting bolts to 20 N.m (15 lb ft). 3. Connect the APP sensor harness connector. 4. Verify that the vehicle meets the following conditions: ^ The vehicle is not in a Reduced Engine Power mode. ^ The ignition is ON. ^ The engine is OFF. 5. Connect a scan tool in order to test for a proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Inspect the carpet fit under the accelerator pedal. 8. Install the left IP lower closeout insulator panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4573 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4574 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4575 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4576 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4577 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4578 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4579 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4580 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4581 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4582 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4583 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4584 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4585 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4586 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4587 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4588 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4589 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4590 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4591 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4592 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4593 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4594 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4595 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4596 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4597 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4598 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4599 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4600 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4601 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4602 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4603 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 4604 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Take care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. Do not drop or roughly handle the MAF/IAT sensor. 1. Remove air intake resonator. 2. Disconnect the MAF/IAT sensor electrical connector. 3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 4605 2. Install the MAF/IAT sensor on to the air cleaner housing. 3. Tighten the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Connect the MAF/IAT electrical connector. 5. Install air intake resonator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4611 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4612 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4613 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4614 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4615 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4616 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4617 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4618 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4619 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4620 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4621 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4622 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4623 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4624 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4625 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4626 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4627 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4628 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4629 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4630 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4631 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4632 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4633 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4634 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4635 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4636 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4637 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 Camshaft Position (CMP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4642 Camshaft Position Sensor: Description and Operation The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4643 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. Camshaft Position Sensor (CMP) 1. Remove the engine sight shield, as necessary. 2. Disconnect the CMP sensor electrical connector. 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor. INSTALLATION PROCEDURE Camshaft Position Sensor (CMP) 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CMP sensor electrical connector. 4. Install the engine sight shield, as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4647 Engine Coolant Temperature (ECT) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4648 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.. 3. Drain the cooling system below the level of the ECT sensor. Refer to Draining and Filling Cooling System in Cooling System. 4. Lower the vehicle. 5. Disconnect the electrical connector from the engine coolant temperature (ECT) sensor. 6. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: ^ Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. ^ Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4649 1. Coat the ECT sensor threads with sealer GM P/N 12346004 or the equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4655 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4656 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4657 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4658 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4659 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4660 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4661 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4662 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4663 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4664 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4665 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4666 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4667 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4671 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4672 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4673 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4674 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4675 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4676 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4677 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4678 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4679 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4680 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4681 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4682 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4683 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4684 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4685 Crankshaft Position (CKP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4686 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at Top Dead Center (TDC). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module (PCM) for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. Observe the fuel cut-off for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: ^ Block the drive wheels. ^ Apply the vehicles parking brake. ^ Cycle the ignition from OFF to ON. ^ Apply and hold the brake pedal. ^ Start and idle the engine. ^ Turn OFF the AC. ^ Place the vehicle's transmission in Park (A/T) or Neutral (M/T). ^ The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. With the scan tool, enable the CKP system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-off is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine Mechanical. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4689 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure when the crankshaft position sensor is removed or replaced. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the starter. 4. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4690 5. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 6. Remove the CKP sensor retaining bolt. 7. Remove the CKP sensor. INSTALLATION PROCEDURE Crankshaft Position Sensor (CKP) 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor retaining fastener. Tighten Tighten the bolt to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4691 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4695 Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The Powertrain Control Module (PCM) sends the fuel level information via the class 2 circuit to the Instrument Panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4696 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the retaining clip (6) from the fuel level sensor connector. 4. Disconnect the electrical connector (7) from under the fuel sender cover. 5. Remove the sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip (4). 3. Connect the electrical connector (7) to the fuel level sensor. 4. Connect the retaining clip (6) to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4700 Fuel Tank Pressure (FTP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4701 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4702 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Remove the fuel pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel pressure sensor (1). 2. Install the fuel tank. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4706 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4707 Intake Air Temperature Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Take care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. Do not drop or roughly handle the MAF/IAT sensor. 1. Remove air intake resonator. 2. Disconnect the MAF/IAT sensor electrical connector. 3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4708 2. Install the MAF/IAT sensor on to the air cleaner housing. 3. Tighten the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Connect the MAF/IAT electrical connector. 5. Install air intake resonator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set Knock Sensor: Customer Interest Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-023A Date: June, 2002 TECHNICAL Subject: Audible Spark Knock (Detonation), MIL Illuminated, DTC P0332 Set (Replace Rear Bank Knock Sensor and RTV Area Around Sensor) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird with 5.7L Engine (VIN G - RPO LS1) 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalance 1999-2002 GMC Sierra, Yukon, Yukon XL 2002 Cadillac Escalade, Escalade EXT with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, N, U - RPOS LR4, LM7, L59, L09, L04) This bulletin is being revised to add Cadillac Escalade and Cadillac Escalade EXT to the Models. Please discard Corporate Bulletin Number 02-06-04-023 (Section 6 - Engine/Propulsion System). Condition Some customers may comment on a mild to severe engine ping (commonly referred to as spark knock), usually worse during acceleration and/or an illuminated MIL. Upon investigation, the technician may find DTC P0332 set. Cause This condition may be the result of corrosion of the rear bank knock sensor due to water intrusion into the sensor cavity. This condition is more apparent on vehicles in which customers frequently wash the engine compartment. Correction Replace the rear bank knock sensor and build a dam (wall) around the sensor using RTV to divert water away from the sensor. Use the procedure and part number listed. 1. Remove the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. 2. Remove the wiring harness assembly from the knock sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 4717 3. Remove the rear bank knock sensor. 4. Install the new rear bank knock sensor. Tighten Tighten the knock sensor to 20 N.m (15 lb ft). 5. Install the wiring harness assembly to the knock sensor. 6. Apply a bead of RTV silicone sealant approximately 9 mm (3/8 in) wide and 6 mm (1/4 in) high along the outside edge of the ridge on the engine block valley cover around the rear bank knock sensor. DO NOT form a complete circle. Leave the rear section open as shown. 7. From the underside of the intake manifold, completely remove the rear intake manifold seal (foam material). 8. Install the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 4718 For vehicles repaired under warranty, use the table as shown DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set Knock Sensor: All Technical Service Bulletins Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-023A Date: June, 2002 TECHNICAL Subject: Audible Spark Knock (Detonation), MIL Illuminated, DTC P0332 Set (Replace Rear Bank Knock Sensor and RTV Area Around Sensor) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird with 5.7L Engine (VIN G - RPO LS1) 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalance 1999-2002 GMC Sierra, Yukon, Yukon XL 2002 Cadillac Escalade, Escalade EXT with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, N, U - RPOS LR4, LM7, L59, L09, L04) This bulletin is being revised to add Cadillac Escalade and Cadillac Escalade EXT to the Models. Please discard Corporate Bulletin Number 02-06-04-023 (Section 6 - Engine/Propulsion System). Condition Some customers may comment on a mild to severe engine ping (commonly referred to as spark knock), usually worse during acceleration and/or an illuminated MIL. Upon investigation, the technician may find DTC P0332 set. Cause This condition may be the result of corrosion of the rear bank knock sensor due to water intrusion into the sensor cavity. This condition is more apparent on vehicles in which customers frequently wash the engine compartment. Correction Replace the rear bank knock sensor and build a dam (wall) around the sensor using RTV to divert water away from the sensor. Use the procedure and part number listed. 1. Remove the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. 2. Remove the wiring harness assembly from the knock sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 4724 3. Remove the rear bank knock sensor. 4. Install the new rear bank knock sensor. Tighten Tighten the knock sensor to 20 N.m (15 lb ft). 5. Install the wiring harness assembly to the knock sensor. 6. Apply a bead of RTV silicone sealant approximately 9 mm (3/8 in) wide and 6 mm (1/4 in) high along the outside edge of the ridge on the engine block valley cover around the rear bank knock sensor. DO NOT form a complete circle. Leave the rear section open as shown. 7. From the underside of the intake manifold, completely remove the rear intake manifold seal (foam material). 8. Install the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 4725 For vehicles repaired under warranty, use the table as shown DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Page 4726 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4729 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4730 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4731 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4732 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4733 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4736 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4737 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4738 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4739 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4740 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4741 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4742 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4743 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4744 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4745 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4746 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4747 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4748 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4749 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4750 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4751 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4752 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4753 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4754 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4755 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4756 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4757 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4758 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4759 Knock Sensor (KS) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4760 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: ^ The broadband single wire sensor ^ The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: ^ All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. ^ The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near Top Dead Center (TDC) of the firing stroke. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4761 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Remove the knock sensor wiring harness assembly. 3. Remove the knock sensor (KS). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4762 1. Install the knock sensor. Tighten Torque the sensor to 20 N.m (15 lb ft). 2. Install the knock sensor wiring harness assembly. 3. Install the intake manifold. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4766 Manifold Absolute Pressure (MAP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4767 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector. 3. Remove the MAP sensor (1) from the intake manifold. INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4768 1. Install the MAP sensor (1). Push the MAP sensor down in order to engage the sensor into the retainer. 2. Connect the MAP sensor electrical connector. 3. Install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4777 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4778 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4779 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4780 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4781 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4782 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4783 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4784 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4785 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4786 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4787 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4788 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4789 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4790 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4791 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4792 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4793 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4794 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4795 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4796 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4797 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4798 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4799 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4800 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4801 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4802 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4803 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4804 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4805 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4806 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4807 Oxygen Sensor: Connector Views Delphi Heated Oxygen Sensor (H02S) Bank 1 Sensor 2 (Delphi) Heated Oxygen Sensor (H02S) Bank 1 Sensor 1 (Delphi) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4808 Heated Oxygen Sensor (H02S) Bank 2 Sensor 1 (Delphi) Heated Oxygen Sensor (H02S) Bank 2 Sensor 2 (Delphi) Denso Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4809 Heated Oxygen Sensor (H02S) Bank 1 Sensor 2 (Denso) Heated Oxygen Sensor (H02S) Bank 1 Sensor 1 (Denso) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4810 Heated Oxygen Sensor (H02S) Bank 2 Sensor 1 (Denso) Heated Oxygen Sensor (H02S) Bank 2 Sensor 2 (Denso) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4811 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSORS The main function of the pre-catalyst HO2S is to provide the PCM with exhaust stream information in order to maintain proper fueling to hold emissions within acceptable levels. These oxygen sensors are always located between the exhaust manifold and the 3-way Catalytic Converter (TWC). After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases. The PCM uses the signal voltage from the fuel control HO2S in a Closed Loop in order to adjust the fuel injector pulse width. While in a Closed Loop, the PCM can adjust fuel delivery in order to maintain an air to fuel ratio which allows the best combination of emission control and driveability. If the HO2S pigtail wiring, connector, or terminal are damaged, replace the entire HO2S assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must be provided with a clean air reference. This clean air reference is obtained by way of the HO2S wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference. Any attempt to repair the wires, connectors, or terminals could degrade HO2S performance. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 4814 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 4815 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 4816 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 4817 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 4818 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 4819 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 4820 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4826 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4827 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4828 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4829 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4830 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4831 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4832 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4833 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4834 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4835 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4836 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4837 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4838 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4839 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4840 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4841 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4842 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4843 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4844 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4845 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4846 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4847 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4848 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4849 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4850 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4851 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4852 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4853 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4854 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4855 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4856 Throttle Position Sensor: Connector Views Throttle Position (TP) Sensor Throttle Position (TP) Sensor (Dual Track) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4857 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to the Battery Disconnect Caution in Service Precautions. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result. IMPORTANT: If the vehicle is equipped with electronic throttle control (ETC) the throttle position (TP) sensor is NOT serviceable. The throttle body and TP sensor MUST be serviced as a complete assembly. 1. Disconnect the negative battery cable. 2. Remove the generator. 3. Disconnect the throttle position TP sensor electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4858 4. Remove the TP sensor attaching screws (5). 5. Remove the TP sensor (6). 6. Remove the TP sensor O-ring seal (7). INSTALLATION PROCEDURE 1. Install the TP sensor O-ring seal (7) on the TP sensor (6). 2. Install the TP sensor on the throttle body with the throttle valve in the closed position. Verify the TP sensor lever lines up with the TP sensor drive lever on the throttle shaft. NOTE: Refer to the Fastener Notice in Service Precautions. 3. Install the TP sensor attaching screws (5). Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4859 4. Connect the TP sensor electrical connector. 5. Install the generator. 6. Connect the negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 4L60-E Park/Neutral Position Switch Screw .................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E > Page 4865 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E Transmission Position Switch/Sensor: Adjustments 4L60-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E > Page 4868 Transmission Position Switch/Sensor: Adjustments 4L80-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E Transmission Position Switch/Sensor: Service and Repair 4L60-E Park Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 4871 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 4872 Transmission Position Switch/Sensor: Service and Repair 4L80-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 4873 4. Position the tool J41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4878 Accelerator Pedal Position (APP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4879 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position (APP) Sensor The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 3 individual accelerator pedal position sensors within one housing. Three separate signal, low reference, and 5-volt reference circuits are used to connect the APP and the TAC module. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 1.0 volt at 0 pedal travel to above 2.0 volts at 100 percent pedal travel. APP sensor 2 voltage should decrease from above 4.0 volts at 0 pedal travel to below 2.9 volts at 100 percent pedal travel. APP sensor 3 voltage should decrease from above 3.8 volts at 0 percent pedal travel to below 3.1 volts at 100 percent pedal travel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4880 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the left instrument panel (IP) lower closeout insulator panel. 2. Disconnect the accelerator pedal position (APP) sensor harness connector. Remove the accelerator pedal mounting bolts. 3. Remove the APP assembly. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4881 1. Install the APP assembly to the steering column support bracket. NOTE: Refer to the Fastener Notice in Service Precautions. IMPORTANT: Always use a torque wrench in order to obtain the proper torque. 2. Install the accelerator pedal mounting bolts. Tighten Tighten the accelerator pedal mounting bolts to 20 N.m (15 lb ft). 3. Connect the APP sensor harness connector. 4. Verify that the vehicle meets the following conditions: ^ The vehicle is not in a Reduced Engine Power mode. ^ The ignition is ON. ^ The engine is OFF. 5. Connect a scan tool in order to test for a proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Inspect the carpet fit under the accelerator pedal. 8. Install the left IP lower closeout insulator panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4887 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4888 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4889 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4890 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4891 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4892 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4893 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4894 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4895 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4896 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4897 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4898 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4899 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4900 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4901 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4902 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4903 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4904 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4905 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4906 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4907 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4908 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4909 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4910 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4911 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4912 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4913 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4914 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4915 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4916 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4917 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 4918 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Take care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. Do not drop or roughly handle the MAF/IAT sensor. 1. Remove air intake resonator. 2. Disconnect the MAF/IAT sensor electrical connector. 3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 4919 2. Install the MAF/IAT sensor on to the air cleaner housing. 3. Tighten the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Connect the MAF/IAT electrical connector. 5. Install air intake resonator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams Fuel Composition Sensor - W/L59 Only Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 4923 Flexible Fuel Sensor: Description and Operation FUEL COMPOSITION SENSOR DESCRIPTION The Fuel Composition Sensor (FCS), or flex fuel sensor (service parts term), measures the ethanol-gasoline ratio of the fuel being used in a flexible fuel vehicle. Flexible fuel vehicles can be operated with a blend of ethanol and gasoline, up to 85 percent ethanol. In order to adjust the ignition timing and the fuel quantity to be injected, the engine management system requires information about the percentage of ethanol in the fuel. The FCS uses quick-connect style fuel connections, an incoming fuel connection, and an outgoing fuel connection. The two connections have different diameters, to prevent incorrect attachment of the fuel lines. All fuel passes through the fuel composition sensor before continuing on to the fuel rail. The fuel composition sensor measures two different fuel related parameters, and sends an electrical signal to the Powertrain Control Module (PCM) to indicate ethanol percentage, and fuel temperature. The fuel composition sensor has a three-wire electrical harness connector. The three wires provide a ground circuit, a power source, and a signal output to the PCM. The power source is vehicle system voltage, +12 volts), and the ground circuit connects to chassis ground. The signal circuit carries both the ethanol percentage and fuel temperature within the same signal, on the same wire. The FCS uses a microprocessor inside the sensor to measure the ethanol percentage and fuel temp, and change an output signal accordingly. The electrical characteristic of the FCS signal is a square-wave digital signal. The signal is both variable frequency and variable pulse width. The frequency of the signal indicates the ethanol percentage, and the pulse width indicates the fuel temperature. The PCM provides an internal pull-up to five volts on the signal circuit, and the FCS pulls the 5 volts to ground in pulses. The output frequency is linear to the percentage of ethanol content in the fuel. The normal range of operating frequency is between 50 and 150 Hertz, with 50 Hertz representing 0 percent ethanol, and 150 Hertz representing 100 percent ethanol. The normal pulse width range of the digital pulses is between 1 and 5 milliseconds, with 1 millisecond representing 40°C (-40°F), and 5 milliseconds representing 125°C (257°F). The microprocessor inside the sensor is capable of a certain amount of self-diagnosis. An output frequency of 170 Hertz indicates either that the fuel is contaminated or contains methanol (it should not), or that an internal sensor electrical fault has been detected. Certain substances dissolved in the fuel can cause the fuel to be contaminated, raising the output frequency to be higher than the actual ethanol percentage should indicate. Examples of these substances include water, sodium chloride (salt), and methanol. It should be noted that it is likely that the FCS will indicate a slightly lower ethanol percentage than what is advertised at the fueling station. This is not a fault of the sensor. The reason has to do with government requirements for alcohol-based motor fuels. Government regulations require that alcohol intended for use as motor fuel be DENATURED. This means that 100 percent pure ethanol is first denatured with approximately 4% percent gasoline, before being mixed with anything else. When an ethanol gasoline mixture is advertised as E85, the 85 percent ethanol was denatured before being blended with gasoline, meaning an advertised E85 fuel contains only about 81 percent ethanol. The FCS measures the actual percentage of ethanol in the fuel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 4924 Flexible Fuel Sensor: Service and Repair FUEL COMPOSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure. 3. Raise the vehicle. 4. Remove the fuel composition sensor fuel composition sensor (FCS) attachment nuts (1). 5. Disconnect the FCS inlet and outlet pipes from the FCS. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 4925 6. Disconnect the FCS electrical connector (1). 7. Remove the FCS and bracket assembly from the frame rail. 8. Remove the FCS bolts and remove from the bracket. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 4926 1. Install the FCS to the bracket and install bolts. Tighten Tighten bolts to 10 N.m (89 lb in). 2. Install FCS and bracket assembly to frame. 3. Install FCS bracket to frame nuts. Tighten Tighten nuts (1) to 17 N.m (13 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 4927 4. Connect the FCS inlet and outlet pipes to the FCS. 5. Connect the FCS electrical connector (1). 6. Lower the vehicle. 7. Start the engine and check for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4933 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4934 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4935 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4936 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4937 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4938 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4939 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4940 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4941 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4942 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4943 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4944 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4945 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4946 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4947 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4948 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4949 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4950 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4951 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4952 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4953 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4954 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4955 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4956 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4957 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4958 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4959 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4960 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4961 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4962 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4963 Throttle Position Sensor: Connector Views Throttle Position (TP) Sensor Throttle Position (TP) Sensor (Dual Track) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 4964 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to the Battery Disconnect Caution in Service Precautions. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result. IMPORTANT: If the vehicle is equipped with electronic throttle control (ETC) the throttle position (TP) sensor is NOT serviceable. The throttle body and TP sensor MUST be serviced as a complete assembly. 1. Disconnect the negative battery cable. 2. Remove the generator. 3. Disconnect the throttle position TP sensor electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 4965 4. Remove the TP sensor attaching screws (5). 5. Remove the TP sensor (6). 6. Remove the TP sensor O-ring seal (7). INSTALLATION PROCEDURE 1. Install the TP sensor O-ring seal (7) on the TP sensor (6). 2. Install the TP sensor on the throttle body with the throttle valve in the closed position. Verify the TP sensor lever lines up with the TP sensor drive lever on the throttle shaft. NOTE: Refer to the Fastener Notice in Service Precautions. 3. Install the TP sensor attaching screws (5). Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 4966 4. Connect the TP sensor electrical connector. 5. Install the generator. 6. Connect the negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4975 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4976 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4977 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4979 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4981 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4982 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4983 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4984 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4985 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4986 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4987 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4988 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4989 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4990 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4991 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4992 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4993 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4994 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4995 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4996 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4997 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4998 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4999 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5000 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5001 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5002 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5003 Camshaft Position (CMP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5004 Camshaft Position Sensor: Description and Operation The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5005 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. Camshaft Position Sensor (CMP) 1. Remove the engine sight shield, as necessary. 2. Disconnect the CMP sensor electrical connector. 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor. INSTALLATION PROCEDURE Camshaft Position Sensor (CMP) 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CMP sensor electrical connector. 4. Install the engine sight shield, as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5011 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5012 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5013 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5014 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5015 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5016 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5017 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5018 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5019 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5020 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5021 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5022 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5023 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5024 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5025 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5026 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5027 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5028 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5029 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5030 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5031 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5032 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5033 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5034 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5035 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5036 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5037 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5038 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5039 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5040 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5041 Crankshaft Position (CKP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5042 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at Top Dead Center (TDC). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module (PCM) for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. Observe the fuel cut-off for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: ^ Block the drive wheels. ^ Apply the vehicles parking brake. ^ Cycle the ignition from OFF to ON. ^ Apply and hold the brake pedal. ^ Start and idle the engine. ^ Turn OFF the AC. ^ Place the vehicle's transmission in Park (A/T) or Neutral (M/T). ^ The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. With the scan tool, enable the CKP system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-off is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine Mechanical. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5045 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure when the crankshaft position sensor is removed or replaced. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the starter. 4. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5046 5. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 6. Remove the CKP sensor retaining bolt. 7. Remove the CKP sensor. INSTALLATION PROCEDURE Crankshaft Position Sensor (CKP) 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor retaining fastener. Tighten Tighten the bolt to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5047 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set Knock Sensor: Customer Interest Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-023A Date: June, 2002 TECHNICAL Subject: Audible Spark Knock (Detonation), MIL Illuminated, DTC P0332 Set (Replace Rear Bank Knock Sensor and RTV Area Around Sensor) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird with 5.7L Engine (VIN G - RPO LS1) 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalance 1999-2002 GMC Sierra, Yukon, Yukon XL 2002 Cadillac Escalade, Escalade EXT with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, N, U - RPOS LR4, LM7, L59, L09, L04) This bulletin is being revised to add Cadillac Escalade and Cadillac Escalade EXT to the Models. Please discard Corporate Bulletin Number 02-06-04-023 (Section 6 - Engine/Propulsion System). Condition Some customers may comment on a mild to severe engine ping (commonly referred to as spark knock), usually worse during acceleration and/or an illuminated MIL. Upon investigation, the technician may find DTC P0332 set. Cause This condition may be the result of corrosion of the rear bank knock sensor due to water intrusion into the sensor cavity. This condition is more apparent on vehicles in which customers frequently wash the engine compartment. Correction Replace the rear bank knock sensor and build a dam (wall) around the sensor using RTV to divert water away from the sensor. Use the procedure and part number listed. 1. Remove the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. 2. Remove the wiring harness assembly from the knock sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 5061 3. Remove the rear bank knock sensor. 4. Install the new rear bank knock sensor. Tighten Tighten the knock sensor to 20 N.m (15 lb ft). 5. Install the wiring harness assembly to the knock sensor. 6. Apply a bead of RTV silicone sealant approximately 9 mm (3/8 in) wide and 6 mm (1/4 in) high along the outside edge of the ridge on the engine block valley cover around the rear bank knock sensor. DO NOT form a complete circle. Leave the rear section open as shown. 7. From the underside of the intake manifold, completely remove the rear intake manifold seal (foam material). 8. Install the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 5062 For vehicles repaired under warranty, use the table as shown DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set Knock Sensor: All Technical Service Bulletins Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-023A Date: June, 2002 TECHNICAL Subject: Audible Spark Knock (Detonation), MIL Illuminated, DTC P0332 Set (Replace Rear Bank Knock Sensor and RTV Area Around Sensor) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird with 5.7L Engine (VIN G - RPO LS1) 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalance 1999-2002 GMC Sierra, Yukon, Yukon XL 2002 Cadillac Escalade, Escalade EXT with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, N, U - RPOS LR4, LM7, L59, L09, L04) This bulletin is being revised to add Cadillac Escalade and Cadillac Escalade EXT to the Models. Please discard Corporate Bulletin Number 02-06-04-023 (Section 6 - Engine/Propulsion System). Condition Some customers may comment on a mild to severe engine ping (commonly referred to as spark knock), usually worse during acceleration and/or an illuminated MIL. Upon investigation, the technician may find DTC P0332 set. Cause This condition may be the result of corrosion of the rear bank knock sensor due to water intrusion into the sensor cavity. This condition is more apparent on vehicles in which customers frequently wash the engine compartment. Correction Replace the rear bank knock sensor and build a dam (wall) around the sensor using RTV to divert water away from the sensor. Use the procedure and part number listed. 1. Remove the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. 2. Remove the wiring harness assembly from the knock sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 5068 3. Remove the rear bank knock sensor. 4. Install the new rear bank knock sensor. Tighten Tighten the knock sensor to 20 N.m (15 lb ft). 5. Install the wiring harness assembly to the knock sensor. 6. Apply a bead of RTV silicone sealant approximately 9 mm (3/8 in) wide and 6 mm (1/4 in) high along the outside edge of the ridge on the engine block valley cover around the rear bank knock sensor. DO NOT form a complete circle. Leave the rear section open as shown. 7. From the underside of the intake manifold, completely remove the rear intake manifold seal (foam material). 8. Install the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 5069 For vehicles repaired under warranty, use the table as shown DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Page 5070 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5073 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5074 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5075 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5076 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5077 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5078 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5079 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5080 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5081 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5082 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5083 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5084 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5085 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5086 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5087 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5088 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5089 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5090 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5091 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5092 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5093 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5094 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5095 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5096 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5097 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5098 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5099 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5100 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5101 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5102 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5103 Knock Sensor (KS) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5104 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: ^ The broadband single wire sensor ^ The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: ^ All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. ^ The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near Top Dead Center (TDC) of the firing stroke. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5105 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Remove the knock sensor wiring harness assembly. 3. Remove the knock sensor (KS). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5106 1. Install the knock sensor. Tighten Torque the sensor to 20 N.m (15 lb ft). 2. Install the knock sensor wiring harness assembly. 3. Install the intake manifold. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Measure with the Key On Engine Off with the fuel pump commanded ON. Vin (V,T,U) Fuel Pressure (gasoline) ..................................................................................................................... ................................................................. 55-62 psi Vin (Z) Fuel Pressure (ethanol) ....................................................................................................................... ................................................................. 48-54 psi These specifications are taken from the Fuel System Diagnosis. For complete testing of fuel pressures and volume see Fuel System Diagnosis, See: Computers and Control Systems/Testing and Inspection Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE CAUTION: ^ Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. ^ Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 1. Install the fuel pressure gauge to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gauge in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gauge. 7. Inspect for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 5113 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST DESCRIPTION Steps 1-2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 5114 Steps 3-7 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 5115 Steps 8-13 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 5116 Steps 14-18 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 5117 Steps 19-25 The numbers below refer to the step numbers on the diagnostic table. 2. This step verifies that the fuel pump is operating. 4. This step tests for an internal fuel leak. If the fuel pressure drops during this test, then an internal loss of pressure is indicated. 6. This step tests the fuel pressure regulator. The fuel pressure regulator is controlled by the engine vacuum. With the engine vacuum applied, the pressure should drop to the specified value. 9. This step inspects the fuel pressure regulator for a fuel leak from the vacuum port. If fuel leaks from the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator. 10. This step tests for a loss of fuel pressure between the fuel feed pipe shut-off adapter and the fuel pump. 11. This step tests for a leaking fuel injector or for a leaking fuel pressure regulator. If the fuel pressure remains constant during this test, the fuel injectors are not leaking fuel. 14. This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, there is a restriction in the fuel return pipe. 16. This step determines if the fuel pressure regulator or the fuel pump is the cause of the low fuel pressure. If the pressure rises above the specified value, the fuel pump is OK. 18. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Thoroughly inspect all fuel electrical circuits. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed ........................................................................................................................................... .............................................................. 500-700 rpm Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Restriction Indicator > Component Information > Description and Operation Air Cleaner Restriction Indicator: Description and Operation Air Cleaner Restriction Indicator The air cleaner restriction indicator is located on the air cleaner assembly between the air filter and the mass air flow (MAF) sensor. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 5133 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 5139 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 5140 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake duct (2). 2. Disconnect the electrical connector from the mass air flow/intake air temperature (MAF/IAT) sensor. 3. Loosen the 4 fasteners (8) securing the air cleaner housing top cover (4). 4. Lift and rotate the top cover (4) of the air cleaner housing to gain access to the air filter element. 5. Lift out the air filter element (5). 6. Inspect the air filter element for dust, dirt, or water. Clean or replace the air filter element if required. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 5141 1. Install the air filter element (5) into the air cleaner housing. 2. Rotate and install the top cover (4) to the air cleaner housing (6). 3. Insert the fasteners (8) to secure the top cover. 4. Connect the MAF/IAT electrical connector. 5. Install the intake duct. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE CAUTION: ^ Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. ^ Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 1. Install the fuel pressure gauge to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gauge in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gauge. 7. Inspect for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 5147 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance Of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 2. Remove the engine sight shield. 3. Loosen the fuel filler cap in order to relieve the fuel tank vapor pressure. 4. Connect the J 34730-1A to the fuel pressure valve. 5. Install the bleed hose of the gauge into an approved container. 6. Open the valve on the gauge to bleed the system pressure. The fuel connections are now safe for servicing. 7. Drain any fuel remaining in the gauge into an approved container. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition System Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection Ignition Cable: Service and Repair Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: ^ Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. ^ Any signs of cracks or splits in the wires. ^ Inspect each boot for the following conditions: Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 5153 Ignition Cable: Service and Repair Spark Plug Wire Replacement REMOVAL PROCEDURE 1. Disconnect the spark plug wire at each spark plug. ^ Twist each spark plug 1/2 turn. ^ Pull only on the boot in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the ignition coil. ^ Twist each spark plug boot 1/2 turn. ^ Pull only on the boot in order to remove the wires from the ignition coil. SPARK PLUG WIRE LENGTH V8 Spark Plug Wire Length V8 ^ The Melco(R), square design, uses a spark plug wire (1) that is 145 mm (5.70 in) length cable seal to cable seal. ^ The Delphi(R), round design uses a spark plug wire (2) that is 110 mm (4.30 in) length cable seal to cable seal. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 5154 Ignition Coils ^ There are 2 different manufacturers for the ignition coils, the Melco(R) (1) square design, and the Delphi(R) (2) round design. These 2 coils use 2 different spark plug wire, and mounting brackets. ^ Melco(R), square design, coil mounting bracket (1). ^ Delphi(R), round design, coil mounting bracket (2). INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 5155 1. Install the spark plug wires at the ignition coil. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: ^ Push sideways on each boot in order to inspect the seating. ^ Reinstall any loose boot. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - New Spark Plugs & Gapping Info. Spark Plug: Technical Service Bulletins Ignition System - New Spark Plugs & Gapping Info. INFORMATION Bulletin No.: 03-06-04-060B Date: July 30 2008 Subject: Information on New Spark Plugs and Gapping Models Attention: Please disregard the Set Gap Per Vehicle Specification statement on the side of an ACOelco(R) Iridium Spark Plug Box. The statement will be removed from the boxes in the future. Supercede: This bulletin is being revised to add the Chevrolet SSR and the 2005 Pontiac GTO. Please discard Corporate Bulletin Number 03-06-04-060A (Section 06 - Engine/Propulsion System). ^ A new spark plug has been released for use in the above vehicles. The new spark plug has an Iridium tip instead of the current Platinum tip. Due to the different tip design the gap of the spark plug has also changed. ^ The new spark plug P/N 12571164 with AC Delco P/N 41-985 is gapped to 1.01 mm (0.040 in) when the spark plug is made. Notice: The spark plug gap is set during manufacturing and should not be changed or damage to the spark plug may result. Any new spark plug found to not be properly gapped should not be used. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 5160 Spark Plug: Specifications This article has been updated with TSB #03-06-04-060B INFORMATION ON NEW SPARK PLUGS AND GAPPING SPARK PLUG GAP.............................................................................................................................. .................................................. 1.01 mm (0.040 in.) ^ A new spark plug has been released for use in the above vehicles. The new spark plug has an Iridium tip instead of the current Platinum tip. Due to the different tip design, the gap of the spark plug has also changed. ^ The new spark plug, P/N 12571164 with AC Delco P/N 41-985, is gapped to 1.01mm (0.040 inches) when the spark plug is made. Notice: The spark plug gap is set during manufacturing and should not be changed or damage to the spark plug may result. Any new spark plug found to not be properly gapped should not be used. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 5161 Spark Plug: Application and ID AC Plug Type ...................................................................................................................................... ................................................................... 25171803 NGK Plug Type .................................................................................................................................... ................................................................. 12567759 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection Spark Plug: Service and Repair Spark Plug Inspection SPARK PLUG USAGE ^ Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. ^ Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION ^ Inspect the terminal P05 (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. ^ Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 5164 ^ Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). ^ Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. ^ A rattling sound indicates internal damage. ^ A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. ^ Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION ^ Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. ^ Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures ^ Leaking fuel injectors ^ Excessive fuel pressure ^ Restricted air filter element ^ Incorrect combustion Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 5165 - Reduced ignition system voltage output ^ Weak coils ^ Worn ignition wires ^ Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. ^ Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 5166 Spark Plug: Service and Repair Spark Plug Replacement REMOVAL PROCEDURE 1. Remove the spark plug wires. 2. Loosen each spark plug 1 or 2 turns. 3. Brush or air blast away any dirt from around the spark plugs. 4. Remove the spark plugs 1 at a time. Place each plug in a tray marked with the corresponding cylinder numbers. INSTALLATION PROCEDURE 1. Properly position each spark plug washer. 2. Inspect each spark plug gap. Adjust each plug as needed. Specification Spark plug gap: 1.52 mm (0.060 in) NOTE: Refer to Fastener Notice in Service Precautions. 3. Hand start the spark plugs in the corresponding cylinders. 4. Tighten the spark plugs. Tighten ^ For used heads tighten the spark plugs to 15 N.m (11 lb ft). ^ For new aluminum heads tighten the spark plugs to 20 N.m (15 lb ft). ^ For new iron heads, tighten the spark plugs to 30 N.m (22 lb ft). 5. Install the spark plug wires. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1035 x 70% = 725) (150 x 70% = 105). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Engine Compression Test (Electronic Throttle) Compression Check: Testing and Inspection Engine Compression Test (Electronic Throttle) Engine Compression Test (Electronic Throttle) 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gauge at zero and crank the engine through four compression strokes, four puffs. 8. Check the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml. (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Recheck the compression and record the reading. 10. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1035 x 70% = 725) (150 x 70% = 105). Normal-Compression builds up quickly and evenly to the specified compression for each cylinder. - Piston Rings Leaking-Compression is low on the first stroke. Then compression builds up with the following strokes but does not reach normal. Compression improves considerably when you add oil. - Valves Leaking-Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. - If two adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Engine Compression Test (Electronic Throttle) > Page 5172 Compression Check: Testing and Inspection Engine Compression Test (Mechanical Throttle) Engine Compression Test (Mechanical Throttle) 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Block the throttle plate wide open. 6. Start with the compression gauge at zero and crank the engine through four compression strokes, four puffs. 7. Make the compression check for each cylinder. Record the reading. 8. If a cylinder has low compression, inject approximately 15 ml. (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Recheck the compression and record the reading. 9. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1035 x 70% = 725) (150 x 70% = 105). Normal-Compression builds up quickly and evenly to the specified compression for each cylinder. - Piston Rings Leaking-Compression is low on the first stroke. Compression then builds up with the following strokes but does not reach normal. Compression improves considerably when you add oil. - Valves Leaking-Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. - If two adjacent cylinders have lower than normal compression and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5180 Accelerator Pedal Position (APP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5181 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position (APP) Sensor The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 3 individual accelerator pedal position sensors within one housing. Three separate signal, low reference, and 5-volt reference circuits are used to connect the APP and the TAC module. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 1.0 volt at 0 pedal travel to above 2.0 volts at 100 percent pedal travel. APP sensor 2 voltage should decrease from above 4.0 volts at 0 pedal travel to below 2.9 volts at 100 percent pedal travel. APP sensor 3 voltage should decrease from above 3.8 volts at 0 percent pedal travel to below 3.1 volts at 100 percent pedal travel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5182 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the left instrument panel (IP) lower closeout insulator panel. 2. Disconnect the accelerator pedal position (APP) sensor harness connector. Remove the accelerator pedal mounting bolts. 3. Remove the APP assembly. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5183 1. Install the APP assembly to the steering column support bracket. NOTE: Refer to the Fastener Notice in Service Precautions. IMPORTANT: Always use a torque wrench in order to obtain the proper torque. 2. Install the accelerator pedal mounting bolts. Tighten Tighten the accelerator pedal mounting bolts to 20 N.m (15 lb ft). 3. Connect the APP sensor harness connector. 4. Verify that the vehicle meets the following conditions: ^ The vehicle is not in a Reduced Engine Power mode. ^ The ignition is ON. ^ The engine is OFF. 5. Connect a scan tool in order to test for a proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Inspect the carpet fit under the accelerator pedal. 8. Install the left IP lower closeout insulator panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5189 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5190 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5191 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5192 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5193 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5194 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5195 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5207 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5208 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5209 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5210 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5211 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5212 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5213 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5214 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5215 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5216 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5217 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5218 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5219 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 5220 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Take care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. Do not drop or roughly handle the MAF/IAT sensor. 1. Remove air intake resonator. 2. Disconnect the MAF/IAT sensor electrical connector. 3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 5221 2. Install the MAF/IAT sensor on to the air cleaner housing. 3. Tighten the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Connect the MAF/IAT electrical connector. 5. Install air intake resonator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 5225 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 5226 Intake Air Temperature Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Take care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. Do not drop or roughly handle the MAF/IAT sensor. 1. Remove air intake resonator. 2. Disconnect the MAF/IAT sensor electrical connector. 3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 5227 2. Install the MAF/IAT sensor on to the air cleaner housing. 3. Tighten the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Connect the MAF/IAT electrical connector. 5. Install air intake resonator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5233 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5234 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5235 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5236 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5237 Body Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5238 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5239 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5240 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5241 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5242 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5243 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5244 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5245 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5246 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5247 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5248 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5249 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5250 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5251 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5252 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5253 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5254 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5255 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5256 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5257 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5258 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5259 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5260 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5261 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5262 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5263 Body Control Module: Connector Views Body Control Module Connector (BCM) - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5264 Body Control Module (BCM) - C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5265 Body Control Module (BCM) - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5266 Body Control Module: Electrical Diagrams Controlled/Monitored Subsystem References Controlled/Monitored Subsystem References Body Control Module Schematics: Controlled/Monitored Subsystem References Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5267 Exterior Lighting Systems References Exterior Lighting Systems References Body Control Module Schematics: Exterior Lighting Systems References Interior Lighting Systems References Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5268 Interior Lighting Systems References Body Control Module Schematics: Interior Lighting Systems References Power, Ground and Serial Data Power, Ground and Serial Data Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5269 Body Control Module Schematics: Power, Ground And Serial Data Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures IMPORTANT: If any module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not properly configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: ^ The battery is fully charged. ^ The ignition switch is in the RUN position. ^ The DLC is accessible. ^ All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: ^ Inspect all BCM connections. ^ Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to the Theft Deterrent sub-system for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve History DTCs from all modules. 5. Clear all history DTCs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 5272 Body Control Module: Removal and Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable(s). 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the BCM from the sliding bracket. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 5273 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. 4. Install the knee bolster. 5. Connect the negative battery cable(s). 6. Reprogram the BCM. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5279 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5280 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5281 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5282 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5283 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5284 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5285 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5286 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5287 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5288 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5289 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5290 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5291 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5292 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5293 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5294 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5295 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5296 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5297 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5298 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5299 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5300 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5301 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5302 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5303 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5304 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5305 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5306 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5307 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5308 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5309 Camshaft Position (CMP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 5310 Camshaft Position Sensor: Description and Operation The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 5311 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. Camshaft Position Sensor (CMP) 1. Remove the engine sight shield, as necessary. 2. Disconnect the CMP sensor electrical connector. 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor. INSTALLATION PROCEDURE Camshaft Position Sensor (CMP) 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CMP sensor electrical connector. 4. Install the engine sight shield, as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5315 Engine Coolant Temperature (ECT) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5316 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.. 3. Drain the cooling system below the level of the ECT sensor. Refer to Draining and Filling Cooling System in Cooling System. 4. Lower the vehicle. 5. Disconnect the electrical connector from the engine coolant temperature (ECT) sensor. 6. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: ^ Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. ^ Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5317 1. Coat the ECT sensor threads with sealer GM P/N 12346004 or the equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5323 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5327 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5328 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5330 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5331 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5332 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5333 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5334 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5335 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5336 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5337 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5338 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5339 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5340 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5341 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5342 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5343 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5344 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5345 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5346 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5347 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5348 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5349 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5350 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5351 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5352 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5353 Crankshaft Position (CKP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 5354 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at Top Dead Center (TDC). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module (PCM) for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. Observe the fuel cut-off for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: ^ Block the drive wheels. ^ Apply the vehicles parking brake. ^ Cycle the ignition from OFF to ON. ^ Apply and hold the brake pedal. ^ Start and idle the engine. ^ Turn OFF the AC. ^ Place the vehicle's transmission in Park (A/T) or Neutral (M/T). ^ The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. With the scan tool, enable the CKP system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-off is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine Mechanical. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5357 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure when the crankshaft position sensor is removed or replaced. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the starter. 4. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5358 5. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 6. Remove the CKP sensor retaining bolt. 7. Remove the CKP sensor. INSTALLATION PROCEDURE Crankshaft Position Sensor (CKP) 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor retaining fastener. Tighten Tighten the bolt to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5359 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector (DLC) Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector (DLC) > Page 5364 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 5365 Data Link Connector: Diagrams Splice Pack SP205 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 5366 Data Link Connector (DLC) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 5367 Data Link Connector: Service and Repair REMOVAL PROCEDURE 1. Remove the bolt from the data link connector. 2. Remove the data link connector from the instrument panel. INSTALLATION PROCEDURE 1. Install the data link connector to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the data link connector bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 5371 Throttle Actuator Control (TAC) Motor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations Electronic Throttle Control Module: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 5375 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 5376 Electronic Throttle Control Module: Diagrams Throttle Actuator Control (TAC) Module Connector C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 5377 Throttle Actuator Control (TAC) Module Connector C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 5378 Electronic Throttle Control Module: Description and Operation THROTTLE ACTUATOR CONTROL (TAC) MODULE Throttle Actuator Control (TAC) Module The TAC module is the control center for the electronic throttle system. The TAC module and the powertrain control module (PCM) communicate via a dedicated redundant serial data circuit. The TAC module and the PCM monitor the commanded throttle position and compare the commanded position to the actual throttle position. This is accomplished by monitoring the APP and the TP sensor. These 2 values must be within a calibrated value of each other. The TAC module also monitors each individual circuit of the TP sensor and the APP to verify proper operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 5379 Electronic Throttle Control Module: Service and Repair THROTTLE ACTUATOR CONTROL (TAC) MODULE REPLACEMENT REMOVAL PROCEDURE 1. Release the retainer tab from the left side of the throttle actuator control (TAC) module. 2. Slowly slide the TAC module out of the retaining bracket. 3. Disconnect the TAC module connectors from the TAC module. INSTALLATION PROCEDURE 1. Connect the TAC module connectors to the TAC module. 2. Slide the TAC module into the TAC module bracket. 3. Push the TAC module towards the bracket in order to snap the TAC module into the bracket. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls MIL ON/Misfire/Misfire DTC's Set > Page 5388 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 5394 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 5399 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 5405 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5406 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5409 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5410 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5411 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5412 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5413 Engine Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5414 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5415 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5416 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5417 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5418 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5419 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5420 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5421 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5422 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5423 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5424 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5425 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5426 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5427 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5428 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5429 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5432 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5433 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5434 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5439 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5440 Powertrain Control Module (PCM) C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5441 Powertrain Control Module (PCM) C1 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5442 Powertrain Control Module (PCM) C2 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5443 Powertrain Control Module (PCM) C2 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5444 Powertrain Control Module (PCM) C2 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description Engine Control Module: Description and Operation Electronic Ignition (EI) System Description POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: ^ The Throttle Position (TP) Sensor ^ The Engine Coolant Temperature (ECT) Sensor ^ The Mass Airflow (MAF) sensor ^ The Intake Air Temperature (IAT) Sensor ^ The Vehicle Speed Sensor (VSS) ^ The transmission gear position or range information sensors ^ The Engine Knock Sensors (KS) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 5447 Engine Control Module: Description and Operation Powertrain Control Module (PCM) Description General Information The Powertrain Control Module (PCM) is designed to maintain exhaust emission levels while maintaining excellent driveability and fuel efficiency. The PCM controls the following operations: ^ The fuel control ^ The Ignition Control (IC) ^ The Knock Sensor (KS) system ^ The automatic transmission shift functions ^ The manual transmission ^ The cruise control enable, if equipped ^ The generator ^ The evaporative emissions (EVAP) purge ^ The A/C clutch control, if equipped ^ The secondary air injection (AIR), if equipped ^ The Exhaust Gas Recirculation (EGR) PCM Function The PCM supplies a buffered voltage to various sensors and switches. The PCM controls most components with electronic switches which complete a ground circuit when turned ON. Powertrain Control Module Powertrain Control Module The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is the control center of the vehicle. The PCM controls the following: ^ The fuel metering system ^ The transmission shifting ^ The ignition timing ^ The on-board diagnostics for powertrain functions The PCM constantly monitors the information from various sensors and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic functions for those systems. The PCM can recognize operational problems and alert the driver through the Malfunction Indicator Lamp (MIL) when a malfunction has occurred. When a malfunction is detected, the PCM stores a Diagnostic Trouble Code (DTC) which helps to identify problem areas. This is done to aid the technician in making repairs. The PCM supplies either 5.0 or 12.0 volts to power various sensors and switches. This is done through resistances in the PCM. The resistance is so high in value that a test lamp does not illuminate when connected to the circuit. In some cases, even an ordinary shop voltmeter does not give an accurate reading because the voltmeters resistance is too low. Therefore, a DMM with a minimum of 10 megaohms input impedance is required to ensure accurate voltage readings. The PCM controls output circuits such as the fuel injectors, the Idle Air Control (IAC), the cooling fan relays, etc. by controlling the ground or the power feed circuit through transistors or a device called an output driver module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 5448 Torque Management Torque management is a function of the PCM that reduces engine power under certain conditions. Torque management is performed for the following reasons: 1. To prevent over-stressing the powertrain and driveline components 2. To prevent damage to the vehicle during certain abusive maneuvers 3. To reduce engine speed when the IAC is out of the normal operating range The PCM monitors the following sensors and engine parameters in order to calculate engine output torque: ^ The air/fuel ratio ^ The Mass Air Flow (MAF) sensor ^ The Manifold Absolute Pressure (MAP) Sensor ^ The Intake Air Temperature (IAT) Sensor ^ The spark advance ^ The engine speed ^ The Engine Coolant Temperature (ECT) Sensor ^ The A/C clutch status The PCM monitors the torque converter status, the transmission gear ratio, and the engine speed in order to determine if torque reduction is required. The PCM retards the spark as appropriate to reduce engine torque output if torque reduction is required. The PCM also shuts OFF the fuel to certain injectors in order to reduce the engine power in the case of an abusive maneuver. The following are instances when engine power reduction is likely to be experienced: ^ During transmission upshifts and downshifts ^ During heavy acceleration from a standing start ^ When the clutch pedal is released too quick under a heavy load, 6.0L only ^ When one set of drive axles looses traction while the other set of drive axles are not moving, 4 Wheel Drive only and in 4WD low ^ If the IAC is out of the normal operating range, except 6.0L ^ When the driver is performing harsh or abusive maneuvers such as shifting into gear at high throttle angles or shifting the transmission from reverse to drive to create a rocking motion The driver is unlikely to notice the torque management actions in the first 2 instances. The engine power output is moderate at full throttle in the other cases. The PCM calculates the amount of spark retard necessary to reduce the engine power by the desired amount. The PCM disables the fuel injectors for cylinders 1, 4, 6, and 7 in the case of an abusive maneuver. Basic Knowledge Required Without a basic knowledge of electricity, you will have difficulty using the diagnostic procedures. You should understand the basic theory of electricity and know the meaning of voltage-volts, current-amps, and resistance-ohms. You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. PCM Service Precautions The PCM is designed to withstand normal current draws associated with vehicle operations. Avoid overloading any circuit. When testing for opens or shorts, do not ground any of the PCM circuits unless instructed. When testing for opens or shorts, do not apply voltage to any of the PCM circuits unless instructed. Only test these circuits with a DMM while the PCM connectors remain connected. Engine Controls Information The driveability and emissions information describes the function and operation of the powertrain control module (PCM). The engine controls Information contains the following: ^ Component locations ^ Wiring diagrams ^ PCM terminal end view and terminal definitions ^ Diagnostic System Check-Computers and Controls Systems ^ Diagnostic trouble code (DTC) tables The component system includes the following items: ^ Component and circuit description ^ On-vehicle service for each sub-system ^ Functional checks and diagnostic tables The DTCs also contain diagnostic support information containing circuit diagrams, circuit or system information, and helpful diagnostic information. System Status and Drive Cycle For Inspection/Maintenance The System Status selection is included in the scan tool System Info menu. Several states require that the I/M (OBD II system) pass on-board tests for the major diagnostics prior to having a vehicle emission inspection. This is Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 5449 also a requirement to renew license plates in some areas. Using a scan tool, the technician can observe the System Status, complete or not complete, in order to verify that the vehicle meets the criteria to comply with local area requirements. Using the System Status display, any of the following systems or combination of systems may be monitored for I/M Readiness: ^ The catalyst ^ The Evaporative Emission (EVAP) system ^ The Heated Oxygen Sensors (HO2S) ^ The HO2S heater ^ The Exhaust Gas Recirculation (EGR) system ^ The secondary air injection (AIR) system IMPORTANT: The System Status display indicates only whether or not the test has been completed. The System Status display does not necessarily mean that the test has passed. If a Failed Last Test indication is present for a DTC associated with one of the above systems, diagnosis and repair is necessary in order to meet the I/M requirement. Verify that the vehicle passes all of the diagnostic tests associated with the displayed System Status prior to returning the vehicle to the customer. Refer to the Typical Drive Cycle table, more than one drive cycle may be needed, to use as a guide to complete the I/M System Status tests. Typical Drive Cycle Following a DTC info clear, System Status clears for one or all of these systems. Following a battery disconnect or a PCM replacement, all System Status information clears. Primary System Based Diagnostics There are primary system-based diagnostics which evaluate the system operation and their effect on vehicle emissions. The primary system-based diagnostics are listed below, with a brief description of the diagnostic functionality. Oxygen Sensor Diagnosis Diagnose the fuel control heated oxygen sensors (HO2S) for the following conditions: ^ Heater performance, heater current monitor ^ Response switches, number or switches R/L or L/R ^ Response time, time to switch R/L or L/R ^ Inactive signal, output steady at bias voltage - approximately 450 mV ^ Signal fixed high ^ Signal fixed low Diagnose the catalyst monitor HO2S for the following functions: ^ Heater performance, heater current monitor ^ Signal fixed low ^ Signal fixed high ^ Inactive sensor Heated Oxygen Sensors The main function of the pre-catalyst HO2S is to provide the PCM with exhaust stream information in order to maintain proper fueling to hold emissions within acceptable levels. These oxygen sensors are always located between the exhaust manifold and the 3-way Catalytic Converter (TWC). After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases. The PCM uses the signal voltage from the fuel control HO2S in a Closed Loop in order to adjust the fuel injector pulse width. While in a Closed Loop, the PCM can adjust fuel delivery in order to maintain an air to fuel ratio which allows the best combination of emission control and driveability. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 5450 If the HO2S pigtail wiring, connector, or terminal are damaged, replace the entire HO2S assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must be provided with a clean air reference. This clean air reference is obtained by way of the HO2S wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference. Any attempt to repair the wires, connectors, or terminals could degrade HO2S performance. Catalyst Monitor Heated Oxygen Sensors In order to control emissions of HydroCarbons (HC), Carbon Monoxide (CO), and Oxides Of Nitrogen (NOx), the system uses a TWC. The catalyst promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting the HC and CO into harmless water vapor and carbon dioxide. The catalyst also converts NOx to nitrogen. Catalyst monitor HO2S, post-catalyst HO2S, are always located downstream of the catalytic converter. The PCM has the ability to monitor this process using the post catalyst HO2S. The pre-sensors produce an output signal which indicates the amount of oxygen present in the exhaust gas entering the TWC. The post sensor produces an output signal which indicates the oxygen storage capacity of the catalyst. This in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the pre-HO2S signal is far more active than that produced by the post-HO2S. In addition to catalyst monitoring, the post-HO2S has a limited role in controlling fuel delivery. If the post-HO2S signal indicates a high or low oxygen content for an extended period of time while in a Closed Loop, the PCM adjusts the fuel delivery slightly in order to compensate. Catalyst Monitor Diagnostic Operation The catalyst monitor diagnostic measures oxygen storage capacity of the catalyst converter. In order to do this, the HO2S are installed before and after the TWC. Voltage variations between the sensors allow the PCM to determine the catalyst emission performance. As a catalyst becomes less effective in promoting chemical reactions, the catalysts capacity to store and release oxygen generally degrades. The catalyst monitor diagnostic is based on a correlation between conversion efficiency and oxygen storage capacity. A good catalyst, e.g. 95 percent hydrocarbon conversion efficiency, shows a relatively flat output voltage on the post-catalyst HO2S. A degraded catalyst, 65 percent hydrocarbon conversion, shows a greatly increased activity in output voltage from the post catalyst HO2S. The post-catalyst HO2S is used to measure the oxygen storage and release capacity of the catalyst. A high oxygen storage capacity indicates a good catalyst. Low oxygen storage capacity indicates a failing catalyst. The TWC and the HO2S must be at operating temperature in order to achieve correct oxygen sensor voltages like those shown in the post-catalyst HO2S outputs graphic. The catalyst monitor diagnostic is sensitive to the following conditions: ^ Exhaust leaks ^ HO2S contamination ^ Alternative fuels Exhaust system leaks may cause the following: ^ Prevent a degraded catalyst from failing the diagnostic ^ Cause a false failure for a normally functioning catalyst ^ Prevent the diagnostic from running Some of the contaminants that may be encountered are phosphorus, lead, silica, and sulfur. The presence of these contaminants prevent the TWC diagnostic from functioning properly. Three-Way Catalyst Oxygen Storage Capacity Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 5451 Three-Way Catalyst Oxygen Storage Capacity The PCM must monitor the TWC system for efficiency. In order to accomplish this, the PCM monitors the pre-catalyst and post-catalyst HO2S. When the TWC is operating properly, the post-catalyst (2) HO2S shows significantly less activity than the pre-catalyst (1) HO2S. The TWC stores oxygen during the normal reduction and oxidation process. The TWC releases oxygen during the normal reduction and oxidation process. The PCM calculates the oxygen storage capacity using the difference between the pre-catalyst and post-catalyst HO2S voltage levels. Whenever the sensor activity of the post-catalyst (2) HO2S nears the sensor activity of the pre-catalyst (1) HO2S, the catalysts efficiency is degraded. Aftermarket HO2S characteristics may be different from the original equipment manufacturer sensor. This may lead to a false pass or a false fail of the catalyst monitor diagnostic. Similarly, if an aftermarket catalyst does not contain the same amount of precious metal content as the original part, the correlation between oxygen storage and conversion efficiency may be altered enough to set a false DTC. Misfire Monitor Diagnostic Operation The misfire monitor diagnostic is based on crankshaft rotational velocity, aka reference period, variations. The PCM determines crankshaft rotational velocity using the Crankshaft Position (CKP) Sensor and Camshaft Position (CMP) Sensor. When a cylinder misfires, the crankshaft slows down momentarily. By monitoring the crankshaft and CMP sensor signals, the PCM can calculate when a misfire occurs. For a non-catalyst damaging misfire, the diagnostic is required to monitor a misfire present for between 1,000-3,200 engine revolutions. For catalyst damage misfire, the diagnostic responds to the misfire within 200 engine revolutions Rough roads may cause false misfire detection. A rough road applies sudden torque variations to the drive wheels and drivetrain. This torque can intermittently decrease the crankshaft rotational velocity. The Antilock Braking (ABS) System detects uneven speed between the vehicles wheels and sends data via the serial data bus to the PCM to disable the misfire monitor until the rough road is no longer detected. On automatic transmission equipped vehicles, the Torque Converter Clutch (TCC) disables whenever a misfire is detected. Disabling the TCC isolates the engine from the rest of the drive line and minimizes the affect of the drive wheel inputs on crankshaft rotation. When the TCC has disabled as a result of misfire detection, the TCC is re-enabled after approximately 3,200 engine revolutions if no misfire is detected. The TCC remains disabled whenever the misfire is detected, with or without a DTC set. This allows the misfire diagnostic to reevaluate the system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 5452 Whenever a cylinder misfires, the misfire diagnostic counts the misfire and notes the crankshaft position at the time the misfire occurred. A current and a history misfire counter is maintained for each cylinder. The misfire current counters, Misfire Cur #1-8, indicate the number of firing events out of the last 200 cylinder firing events which were misfires. The misfire current counters displays real time data without a misfire DTC stored. The misfire history counters, Misfire Hist #1-8, indicate the total number of cylinder firing events which were misfires. The misfire history counters display 0 until the misfire diagnostic has failed and a DTC P0300 is set. Once the misfire DTC sets, the misfire history counters will be updated every 200 cylinder firing events. The Misfire counters graphic illustrates how these misfire counters are maintained. When crankshaft rotation is erratic, the PCM detects a misfire condition. Because of this erratic condition, the data that is collected by the diagnostic can sometimes incorrectly identify which cylinder is misfiring. The Misfire Counters graphic shows there are misfires counted from more than one cylinder. Cylinder #1 has the majority of counted misfires. In this case, the misfire counters would identify cylinder #1 as the misfiring cylinder. The misfires in the other counters were just background noise caused by the erratic rotation of the crankshaft. If the number of accumulated misfires is sufficient for the diagnostic to identify a true misfire, the diagnostic will set DTC P0300-Misfire Detected. The illustration depicts an accumulation in the history buffers. If two cylinders in sequential tiring order are both misfiring, the first misfiring cylinder will accumulate misfires in the cylinder buffer, but the second misfiring cylinder will not. This is because the PCM compares a misfiring cylinder with the cylinder 90 degrees prior to that cylinder in the firing order. Therefore the PCM would be comparing crankshaft speed of the second misfiring cylinder to an already suspect cylinder. The PCM however, will be able to detect both misfiring cylinders after the engine exceeds 2,000 RPM. This is because the PCM then starts to compare misfires to the opposing cylinder rather than the previous cylinder in the firing order. Use Techline equipment to monitor the misfire counter data on applicable vehicles. Knowing which specific cylinders misfire can lead to the root cause. Using the information in the misfire counters identifies which cylinders are misfiring. If the counters indicate cylinders number 1 and 4 misfired, look for a circuit or component common to both cylinders. The misfire diagnostic may indicate a fault due to a temporary fault not necessarily caused by a vehicle emission system malfunction. Examples include the following items: ^ Contaminated fuel Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 5453 ^ Running out of fuel ^ Fuel fouled spark plugs ^ Basic engine fault Fuel Trim System Operation The fuel trim system monitors the averages of short-term and long-term fuel trim values. If these fuel trim values stay at the individual limits for a calibrated period of time, a malfunction is indicated. The fuel trim diagnostic compares the average of short and long-term fuel trim values. If either value is within the thresholds, a pass is recorded. If either value is outside the thresholds, a rich or lean fuel trim DTC will set. Comprehensive Component Monitor Diagnostic Comprehensive component monitoring diagnostics are required to monitor emissions-related input and output powertrain components. Input Components The PCM monitors the input components for circuit continuity and out-of-range values. This includes performance checking. Performance checking refers to indicating a fault when the signal from a sensor does not seem reasonable, such as a Throttle Position (TP) sensor that indicates high throttle position at low engine loads or manifold Absolute Pressure (MAP) Voltage. The input components may include, but are not limited to, the following sensors: ^ The Vehicle Speed (VSS) Sensor ^ The Mass Air Flow (MAF) Sensor ^ The Intake Air Temperature (IAT) Sensor ^ The Crankshaft Position (CKP) Sensor ^ The Knock Sensor (KS) ^ The Throttle Position (TP) Sensor ^ The Engine Coolant Temperature (ECT) Sensor ^ The Camshaft Position (CMP) Sensor ^ The Manifold Absolute Pressure (MAP) Sensor In addition to the circuit continuity and rationality check, the engine coolant temperature (ECT) sensor is monitored for the sensors ability to achieve a steady state temperature to enable Closed Loop fuel control. Output Components Diagnose the output components for the proper response to PCM commands. Components where functional monitoring is not feasible will be monitored for circuit continuity and out-of-range values if applicable. Output components to be monitored include, but are not limited to, the following circuits: ^ The Idle Air Control (IAC) Motor ^ The Evaporative Emission (EVAP) System ^ The electronic transmission controls ^ The A/C relay, if equipped ^ The VSS output ^ The Malfunction Indicator Lamp (MIL) Control ^ The cruise control enable, if equipped Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) Engine Control Module: Service and Repair Powertrain Control Module (PCM) Programming (Off-board) BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: ^ DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. ^ The Off-Board Programming is used in situations where a control module must be programmed without having the vehicle present. The Off-Board Programming Adapter must be used to perform the Off-Board Programming procedure. The adapter allows the control module to power up and allows the Tech 2 to communicate with the control module. ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. Ensure that all connections are secure at the following locations: ^ The Off-Board Programming Adapter ^ The Tech 2 ^ The control module ^ The Techline terminal OFF-BOARD PROGRAMMING 1. Obtain the VIN of the vehicle for which the control module is being programmed. 2. With the Techline terminal, select Service Programming. 3. Select Tech 2, Reprogram ECU, and Off-Board Programming Adapter as the ECU location. 4. Connect the control module, Off-Board Programming Adapter, and the Tech 2 as described on the Techline terminal. Ensure you use the correct harness connector from the Off-Board Programming Adapter kit. 5. With the Tech 2, select Service Programming Request Information function. The Tech 2 communicates with the control module and receives the access code. 6. With the Tech 2, exit the Service Programming Request Information. 7. Disconnect the Tech 2 from the Off-Board Programming Adapter. 8. Connect the Tech 2 to the Techline terminal. 9. Turn ON the Tech 2. 10. With the Techline terminal, enter the VIN of the vehicle that will be receiving the control module. 11. The Techline terminal will display the message, attaching to database. 12. Identify what type of programming that you are performing. 13. Select the appropriate calibration file. 14. Ensure all connections are secure. 15. The Techline terminal displays a summary screen that summarizes your selections. After confirming you choices, the Techline terminal automatically loads the calibration files to the Tech 2. 16. After the download is complete, turn OFF the Tech 2. 17. Disconnect the Tech 2 from the Techline terminal. 18. Connect the Tech 2 to the Off-Board Programming Adapter. 19. With the Tech 2, select Service Programming. IMPORTANT: DO NOT turn OFF the Off-Board Programming Adapter if the programming procedure is interrupted or unsuccessful. Ensure the control module and the Off-Board Programming Adapter connections are secure and the Techline operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. 20. With the Tech 2, select Program. 21. After the download is complete, exit Service Programming. 22. Turn OFF the Off-Board Programming Adapter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 5456 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Programming (On-Board) BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customers concern. Ensure the following conditions are met before programming a control module: ^ Vehicle system voltage There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicle's battery. ^ Twilight sentinel ^ Interior lights ^ Daytime running lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. Refer to the Owners manual. ^ HVAC systems ^ Cooling System fans, etc. ^ The ignition is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. ^ All tool connections are secure. RS-232 - The connection at the DLC is secure. - Voltage supply circuits ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. REMOTE PROGRAMMING 1. Turn OFF the ignition. 2. Install the Tech 2 to the data link connector (DLC). 3. Turn ON the ignition, with the engine OFF. 4. Turn OFF all vehicle accessories. 5. With the Tech 2, select Service Programming. 6. Identify vehicle information as requested by the Tech 2. 7. Select the type of module you are programming. 8. Select the type of programming to be performed. 9. Verify the displayed VIN with the vehicle VIN. If the displayed VIN does not match the actual VIN, write down the actual VIN and correct the VIN at the Techline terminal. 10. When complete, Exit Service Programming. 11. Turn OFF the Tech 2 and disconnect the Tech 2 from the vehicle. 12. Turn OFF the ignition. 13. Connect the Tech 2 to the Techline terminal. 14. Select Service Programming. 15. Select Tech 2 as the tool you are using. 16. Select the type of programming to be performed. 17. Verify the displayed VIN with the vehicle VIN. Correct the VIN as necessary. 18. Select the type of module you are programming. 19. Identify what type of programming that you are performing. ^ Normal-This type of programming is for updating an existing calibration or programming a new controller. ^ Vehicle configuration index (VCI)-This selection is used if the vehicle VIN is unavailable or not recognized by the Techline terminal. Observe, you will need to contact the Techline Customer Support center to use this option. ^ Reconfigure-This is to reconfigure a vehicle, such as tire size and axle ratio changes. 20. Select the appropriate calibration file. 21. Ensure all connections are secure. 22. Select Reprog to initiate the download of the new calibration to the Tech 2. 23. After the download is complete, turn OFF the Tech 2. 24. Disconnect the Tech 2 from the Techline terminal. 25. Install the Tech 2 to the data link connector (DLC). 26. Turn ON the Tech 2. 27. Turn ON the ignition, with the engine OFF. 28. Select Service Programming. IMPORTANT: DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all the PCM and DLC Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 5457 connections are secure and the Techline(TM) operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. Refer to Powertrain Control Module (PCM) Replacement. 29. Select Program. 30. After the download is complete, EXIT Service Programming. 31. Turn OFF the ignition for 30 seconds. 32. Turn OFF the Tech 2. 33. If a control module is replaced the following service procedures must be performed: ^ CKP System Variation Learn Procedure ^ Inspection/Maintenance (I/M) Complete System Set Procedure ^ Programming Theft Deterrent System Components PROGRAMMING VERIFICATION 1. With a scan tool, clear the DTCs. 2. Attempt to start the engine. 3. Repeat the Service Programming procedure if the engine does not start or operates poorly. Perform the following procedures before programming the PCM: ^ Ensure the control module and DLC connections are OK. ^ Ensure the Techline operating software is up to date. ^ Ensure the calibration part number is correct for the vehicle. 4. Attempt to program the control module. If the control module still cannot be programmed properly, replace the control module. Refer to Powertrain Control Module (PCM) Replacement. You must program the replacement control module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 5458 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Replacement Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. ^ Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. ^ The replacement PCM must be programmed Removal Procedure 1. Release the PCM cover mounting holes (1,5) away from the mounting tabs on the PCM mounting bracket. 2. Release the PCM cover (8) from the mounting bracket. 3. Remove the PCM cover. NOTE: ^ Refer to PCM and ESD Notice in Service Precautions. ^ In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 4. Disconnect the PCM harness connectors (6). 5. Release the spring latch (2) from the PCM. 6. Release the PCM mounting tabs (3) from the PCM. 7. Remove the PCM (4) from the engine compartment. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 5459 1. Install the PCM (4) to the PCM mounting bracket (7) ensuring that the mounting tabs (3) are engaged. 2. Secure the spring latch (2) to the PCM. NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the PCM connectors (6) to the PCM (4). Tighten Tighten the PCM connector end fasteners to 8 N.m (71 lb in). 4. Install the PCM cover (8) to the PCM mounting bracket (7), ensuring the mounting tabs on the PCM mounting bracket are engaged into the mounting holes in the PCM cover. 5. If a new PCM is being installed, program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 5460 Engine Control Module: Service and Repair Service Programming System (SPS) The Service Programming System (SPS) allows a technician to program a control module through the Data Link Connector (DLC). The information transfer circuit that is used at the DLC is the same serial data circuit used by the scan tool for retrieving Diagnostic Trouble Codes (DTCs), displaying data, clearing DTCs, etc. This procedure offers the ability to install software/calibrations matched to a particular vehicle. Most control modules have 2 types of memory. The software/calibrations reside in the flash memory. The two types of memory are listed below: ^ Electrically Erasable Programmable Read Only Memory (EEPROM) This type of memory allows selected portions of memory to be programmed while other portions remain unchanged. Certain learned values reside in the EEPROM, such as: ^ The Vehicle Identification Number (VIN) ^ The crankshaft variation learned position ^ The software/calibrations identification numbers ^ The control module security information ^ Flash Read Only Memory - Flash Memory ^ Flash memory has increased memory storage capacity. During programming, all information within this type of memory is erased, and then replaced with entirely new information. Service Programming Methods The 4 methods of programming a control module and the proper tools for each method are as follows: ^ Remote Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle ^ Pass Thru Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle. ^ Off-Board Remote Programming, vehicle NOT available: The Tech 2 or other scan tool, Off-board Programming Adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle ^ Off-Board Pass Thru Programming - The Tech 2 or other scan tool, off-board programming adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle Before Programming A Control Module IMPORTANT: DO NOT program an existing control module with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A control module should only be programmed when the following occurs: ^ When a service procedure instructs you to replace the control module. The service part control module does not contain operating software or calibrations. ^ General Motors Corporation releases an updated software/calibration package. Ensure that the following conditions are met before programming a control module: ^ Vehicle system voltage: There are no charging system concerns. All charging system concerns must be repaired before programming a control module. - The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged before programming the control module. - A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or disable systems such as: ^ Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. ^ Heating, Ventilation, And Air Conditioning (HVAC) systems ^ Engine cooling fans, etc ^ The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. ^ All tool connections are secure: The RS-232 cable - The connection at the DLC - The voltage supply circuits Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 5461 - The OBPA ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. ^ If you are performing the pass-through programming procedure using a notebook computer without the power cord, ensure that the internal battery is fully charged. After Programming a Control Module The powertrain may operate slightly different after a control module software/calibration update. Operating the powertrain through various driving conditions allows the control module to re-learn certain values. The control module must re-learn the following after a software/calibration update: ^ Fuel trim correction ^ Idle Air Control (IAC) learned position ^ Automatic transmission shift adapts Other learned values only re-learn by performing a service procedure. If a control module is replaced the following service procedures may need to be performed: ^ The crankshaft variation learn procedure ^ The engine oil life reset procedure ^ The idle learn procedure ^ The inspection/maintenance complete system set procedure ^ The vehicle theft deterrent password learn procedure ^ The Throttle Position (TP) sensor learn procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5465 Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The Powertrain Control Module (PCM) sends the fuel level information via the class 2 circuit to the Instrument Panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5466 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the retaining clip (6) from the fuel level sensor connector. 4. Disconnect the electrical connector (7) from under the fuel sender cover. 5. Remove the sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip (4). 3. Connect the electrical connector (7) to the fuel level sensor. 4. Connect the retaining clip (6) to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 5470 Fuel Tank Pressure (FTP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 5471 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 5472 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Remove the fuel pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel pressure sensor (1). 2. Install the fuel tank. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations > Page 5476 Idle Air Control (IAC) Valve Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations > Page 5477 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection CIRCUIT DESCRIPTION The engine idle speed is controlled by the idle air control (IAC) valve. The IAC valve is on the throttle body. The IAC valve pintle moves in and out of an idle air passage bore to control air flow around the throttle plate. The valve consists of a movable pintle, driven by a gear attached to a two phase bi-polar permanent magnet electric motor called a stepper motor. The stepper motor is capable of highly accurate rotation, or of movement, called steps. The stepper motor has two separate windings that are called coils. Each coil is fed by two circuits from the powertrain control module (PCM). When the PCM changes polarity of a coil, the stepper motor moves one step. The PCM uses a predetermined number of counts to determine the IAC pintle position. Observe IAC counts with a scan tool. The IAC counts will increment up or down as the PCM attempts to change the IAC valve pintle position. An IAC Reset will occur when the ignition key is turned OFF. First, the PCM will seat the IAC pintle in the idle air passage bore. Second, the PCM will retract the pintle a predetermined number of counts to allow for efficient engine start-up. If the engine idle speed is out of range for a calibrated period of time, an idle speed diagnostic trouble code (DTC) may set. DIAGNOSTIC AIDS Inspect for the following conditions: ^ A skewed high throttle position (TP) sensor ^ Restricted air intake system ^ Objects blocking the IAC passage or throttle bore ^ The correct positive crankcase ventilation (PCV) valve ^ A properly installed PCV valve ^ Proper operation of the PCV valve ^ Proper operation and installation of all air intake components ^ Proper installation and operation of the mass air flow (MAF) sensor, if equipped ^ Evidence of damage or tampering of the following components: The throttle stop screw - The throttle plate - The throttle shaft - The throttle linkage - The cruise control linkage-if equipped ^ Excess deposits in the IAC passage or on the IAC pintle ^ Excess deposits in the throttle bore or on the throttle plate ^ Vacuum leaks ^ Excess load on engine, such as energy-draining conditions of the transmission, power steering, or alternator ^ A high or unstable idle condition-This condition could be caused by a non-IAC system problem that can not be overcome by the IAC valve. Refer to Symptoms - Computers and Controls Systems. See: Testing and Inspection/Symptom Related Diagnostic Procedures ^ A low or unstable idle condition-This condition could be caused by a non-IAC system problem that can not be overcome by the IAC valve. Refer to Symptoms - Computers and Controls Systems. See: Testing and Inspection/Symptom Related Diagnostic Procedures ^ An intermittent condition-If the condition is intermittent, refer to Intermittent Conditions. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Intermittent Conditions TEST DESCRIPTION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations > Page 5478 Steps 1-6 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations > Page 5479 Steps 7-11 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations > Page 5480 Steps 12-19 The numbers below refer to the step numbers on the diagnostic table. 5. This test will determine the ability of the PCM and IAC valve circuits to control the IAC valve. 7. This test will determine the ability of the PCM to provide the IAC valve circuits with a ground. On a normally operating system, the test lamp should not flash while the IAC counts are incrementing. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations > Page 5481 Idle Speed/Throttle Actuator - Electronic: Service and Repair IDLE AIR CONTROL (IAC) VALVE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the idle air control (IAC) valve electrical connector 2. Remove the IAC valve attaching screws (4). 3. Remove the IAC valve (3). 4. Remove the IAC valve O-ring seal (2). NOTE: ^ Do Not push or pull on the IAC valve pintle on IAC valves that have been in service. The force required to move the pintle may damage the threads on the worm drive. ^ Do Not soak the IAC valve in any liquid cleaner or solvent, as damage may result. 5. Clean the IAC valve O-ring sealing surface, the pintle valve seat, and the air passage. ^ Clean the IAC valve using GM cleaner P/N 1052626 or GM X-66A. Use a shop towel or parts brush to remove heavy deposits. ^ If the air passage has heavy deposits, remove the throttle body for complete cleaning. ^ Shiny spots on the pintle or seat are normal and do not indicate misalignment or a bent pintle shaft. 6. Inspect the IAC valve O-ring for cuts, cracks, or distortion. Replace the O-ring if the O-ring is damaged. INSTALLATION PROCEDURE IMPORTANT: If installing a new IAC valve, be sure to replace the IAC valve with an identical part. The pintle shape of the IAC valve and the diameter of the IAC valve are designed for the specific application. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations > Page 5482 1. Measure the distance between the tip of the IAC valve pintle and the mounting surface (1). If the distance is more than 28 mm (1.1 in) use finger pressure to slowly retract the pintle. The force required to retract the pintle of a new valve does not cause damage to the valve. 2. Lubricate the IAC valve O-ring (2) with clean engine oil. 3. Install the IAC valve O-ring (2) on the IAC valve (3). 4. Install the IAC valve (3). 5. Apply LOCTITE 262 to the IAC valve attaching screw threads if necessary. NOTE: Refer to the Fastener Notice in Service Precautions. 6. Install the IAC valve attaching screws (4). Tighten Tighten the screws to 3 N.m (27 lb in). 7. Connect the IAC valve electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > Data Link Connector (DLC) Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > Data Link Connector (DLC) > Page 5487 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > Page 5488 Information Bus: Diagrams Splice Pack SP205 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > Page 5489 Data Link Connector (DLC) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Data Link Communications Information Bus: Description and Operation Data Link Communications DATA LINK COMMUNICATIONS CIRCUIT DESCRIPTION AND OPERATION The Class 2 serial data link allows modules to transmit, receive, or exchange data between each other: ^ HVAC Control Module (HCM) ^ Rear Wheel Steering Module (RWS) ^ Suspension Control Module (SCM) ^ Active Transfer Case (ATC) ^ Electronic Brake Control Module (EBCM) ^ Powertrain Control Module (PCM) ^ Transmission Control Module (TCM) ^ OnStar(R) Module (ONS) ^ Body Control Module (BCM) ^ Instrument Panel Cluster (IPC) ^ Driver Information Center (DIC) ^ Mirror Memory Module (MMM) ^ Memory Seat Module (MSM) ^ Inflatable Restraint Sensing And Diagnostic Module (SDM) CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the class 2 serial data circuit about once every 2 seconds. When the module detects the class 2 serial data circuit shorted, the setting of all other class 2 serial communication DTCs is inhibited and a U1300, U1301, or a U1305 DTC will set. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Data Link Communications > Page 5492 Information Bus: Description and Operation General Description DATA LINK COMMUNICATIONS CIRCUIT DESCRIPTION AND OPERATION The Class 2 serial data link allows modules to transmit, receive, or exchange data between each other: ^ HVAC Control Module (HCM) ^ Rear Wheel Steering Module (RWS) ^ Suspension Control Module (SCM) ^ Active Transfer Case (ATC) ^ Electronic Brake Control Module (EBCM) ^ Powertrain Control Module (PCM) ^ Transmission Control Module (TCM) ^ OnStar(R) Module (ONS) ^ Body Control Module (BCM) ^ Instrument Panel Cluster (IPC) ^ Driver Information Center (DIC) ^ Mirror Memory Module (MMM) ^ Memory Seat Module (MSM) ^ Inflatable Restraint Sensing And Diagnostic Module (SDM) CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the class 2 serial data circuit about once every 2 seconds. When the module detects the class 2 serial data circuit shorted, the setting of all other class 2 serial communication DTCs is inhibited and a U1300, U1301, or a U1305 DTC will set. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview Begin the diagnosis of the Data Link Communications by performing the Diagnostic System Check for the system in which the customer concern is apparent. The Diagnostic System Check will direct you to the correct procedure within the Data Link Communications when a communication malfunction is present. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5495 Information Bus: Symptom Related Diagnostic Procedures A Symptoms - Data Link Communications IMPORTANT: The following steps must be completed before using the symptom tables: 1. Perform the Diagnostic System Check for the subsystem exhibiting the symptoms. The subsystem diagnostic system check will identify where to begin diagnosis of the data link communication system. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Data Link Communications Description and Operation. Visual/Physical Inspection ^ Inspect for aftermarket devices that could affect the operation of the serial data communications systems. Refer to Checking Aftermarket Accessories in Diagnostic Aids. ^ Inspect the easily accessible systems or visible system components for obvious damage or conditions that could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in Diagnostic Aids. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: ^ Scan Tool Does Not Power Up ^ Scan Tool Does Not Communicate with Class 2 Device Scan Tool Does Not Communicate With Class 2 Device CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. Connecting a scan tool to the DLC allows communication with the modules for diagnostic purposes. DTCs may be set due to this symptom and during this diagnostic procedure. Complete the diagnostic procedure in order to ensure all the DTCs are diagnosed and cleared from memory. DIAGNOSTIC AIDS ^ The BCM detects that the ignition is ON and sends the appropriate power mode message to the other modules. Therefore, the BCM must be connected to the DLC for any other module to communicate with the scan tool. ^ When the class 2 serial data circuit: ^ is shorted to ground ^ is shorted to voltage The following DTCs may set: ^ U1300 ^ U1301 ^ U1305 TEST DESCRIPTION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5496 Steps 1-4 Steps 5-10 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5497 Steps 11-18 The numbers below refer to the step numbers on the diagnostic table. 2. A partial loss of communication in the class 2 serial data circuit uses a different procedure than a total loss of communication of the class 2 serial data circuit. 4. The following DTCs may be retrieved with a history status. These DTCs are not the cause of the present condition. ^ U1300 ^ U1301 ^ U1305 6. A State of Health DTC with a history status may be present along with a U1000 or U1255 with a current status. This indicates that the malfunction occurred when the ignition was on. 10. Normal class 2 serial data communication cannot take place until the power mode master (PMM) module sends the appropriate power mode Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5498 message. If the PMM does not send a wake-up message, other modules on the class 2 serial data circuit may not communicate. 15. If there are no current DTCs that begin with the letter "U", the communication concern has been repaired. 16. The communication concern may have prevented diagnosis of the customer complaint. Scan Tool Does Not Power Up CIRCUIT DESCRIPTION The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: ^ Scan tool power battery positive voltage at terminal 16. ^ Scan tool power ground at terminal 4. ^ Common signal ground at terminal 5. The scan tool will power up with the ignition off. Some modules however, will not communicate unless the ignition is on and the power mode master (PMM) module sends the appropriate power mode message. TEST DESCRIPTION Steps 1-4 The number below refers to the step number on the diagnostic table. 4. If the battery positive voltage and ground circuits of the DLC are functioning properly. The malfunction must be due to the scan tool. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set Knock Sensor: Customer Interest Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-023A Date: June, 2002 TECHNICAL Subject: Audible Spark Knock (Detonation), MIL Illuminated, DTC P0332 Set (Replace Rear Bank Knock Sensor and RTV Area Around Sensor) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird with 5.7L Engine (VIN G - RPO LS1) 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalance 1999-2002 GMC Sierra, Yukon, Yukon XL 2002 Cadillac Escalade, Escalade EXT with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, N, U - RPOS LR4, LM7, L59, L09, L04) This bulletin is being revised to add Cadillac Escalade and Cadillac Escalade EXT to the Models. Please discard Corporate Bulletin Number 02-06-04-023 (Section 6 - Engine/Propulsion System). Condition Some customers may comment on a mild to severe engine ping (commonly referred to as spark knock), usually worse during acceleration and/or an illuminated MIL. Upon investigation, the technician may find DTC P0332 set. Cause This condition may be the result of corrosion of the rear bank knock sensor due to water intrusion into the sensor cavity. This condition is more apparent on vehicles in which customers frequently wash the engine compartment. Correction Replace the rear bank knock sensor and build a dam (wall) around the sensor using RTV to divert water away from the sensor. Use the procedure and part number listed. 1. Remove the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. 2. Remove the wiring harness assembly from the knock sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 5507 3. Remove the rear bank knock sensor. 4. Install the new rear bank knock sensor. Tighten Tighten the knock sensor to 20 N.m (15 lb ft). 5. Install the wiring harness assembly to the knock sensor. 6. Apply a bead of RTV silicone sealant approximately 9 mm (3/8 in) wide and 6 mm (1/4 in) high along the outside edge of the ridge on the engine block valley cover around the rear bank knock sensor. DO NOT form a complete circle. Leave the rear section open as shown. 7. From the underside of the intake manifold, completely remove the rear intake manifold seal (foam material). 8. Install the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 5508 For vehicles repaired under warranty, use the table as shown DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set Knock Sensor: All Technical Service Bulletins Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-023A Date: June, 2002 TECHNICAL Subject: Audible Spark Knock (Detonation), MIL Illuminated, DTC P0332 Set (Replace Rear Bank Knock Sensor and RTV Area Around Sensor) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird with 5.7L Engine (VIN G - RPO LS1) 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalance 1999-2002 GMC Sierra, Yukon, Yukon XL 2002 Cadillac Escalade, Escalade EXT with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, N, U - RPOS LR4, LM7, L59, L09, L04) This bulletin is being revised to add Cadillac Escalade and Cadillac Escalade EXT to the Models. Please discard Corporate Bulletin Number 02-06-04-023 (Section 6 - Engine/Propulsion System). Condition Some customers may comment on a mild to severe engine ping (commonly referred to as spark knock), usually worse during acceleration and/or an illuminated MIL. Upon investigation, the technician may find DTC P0332 set. Cause This condition may be the result of corrosion of the rear bank knock sensor due to water intrusion into the sensor cavity. This condition is more apparent on vehicles in which customers frequently wash the engine compartment. Correction Replace the rear bank knock sensor and build a dam (wall) around the sensor using RTV to divert water away from the sensor. Use the procedure and part number listed. 1. Remove the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. 2. Remove the wiring harness assembly from the knock sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 5514 3. Remove the rear bank knock sensor. 4. Install the new rear bank knock sensor. Tighten Tighten the knock sensor to 20 N.m (15 lb ft). 5. Install the wiring harness assembly to the knock sensor. 6. Apply a bead of RTV silicone sealant approximately 9 mm (3/8 in) wide and 6 mm (1/4 in) high along the outside edge of the ridge on the engine block valley cover around the rear bank knock sensor. DO NOT form a complete circle. Leave the rear section open as shown. 7. From the underside of the intake manifold, completely remove the rear intake manifold seal (foam material). 8. Install the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 5515 For vehicles repaired under warranty, use the table as shown DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Page 5516 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5519 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5520 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5521 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5522 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5523 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5524 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5525 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5526 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5527 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5528 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5529 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5530 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5531 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5532 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5533 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5534 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5535 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5536 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5537 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5538 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5539 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 Knock Sensor (KS) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 5550 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: ^ The broadband single wire sensor ^ The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: ^ All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. ^ The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near Top Dead Center (TDC) of the firing stroke. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 5551 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Remove the knock sensor wiring harness assembly. 3. Remove the knock sensor (KS). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 5552 1. Install the knock sensor. Tighten Torque the sensor to 20 N.m (15 lb ft). 2. Install the knock sensor wiring harness assembly. 3. Install the intake manifold. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Always On CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. MIL OPERATION The MIL is located on the instrument panel (IP). MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. ^ The MIL illuminates during a bulb test and a system test. ^ A DTC will be stored if a MIL is requested by the diagnostic. MIL ILLUMINATION ^ The MIL will illuminate with ignition switch ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Intermittent Conditions TEST DESCRIPTION Steps 1-6 The number below refers to the step numbers on the diagnostic table. 2. The step determines if the condition is with the MIL control circuit or the PCM. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 5557 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Inoperative CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. There should be a steady MIL with the ignition ON and the engine OFF. MIL OPERATION The MIL is located on the instrument panel (IP). MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. ^ The MIL illuminates during a bulb test and a system test. ^ A DTC will be stored if a MIL is requested by the diagnostic. MIL ILLUMINATION ^ The MIL will illuminate with ignition switch ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Intermittent Conditions TEST DESCRIPTION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 5558 Steps 1-14 The numbers below refer to the step numbers on the diagnostic table. 3. This step determines if the condition is with the MIL control circuit or the PCM. 4. This step determines if a voltage is being applied to the control circuit. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 5562 Manifold Absolute Pressure (MAP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 5563 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector. 3. Remove the MAP sensor (1) from the intake manifold. INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 5564 1. Install the MAP sensor (1). Push the MAP sensor down in order to engage the sensor into the retainer. 2. Connect the MAP sensor electrical connector. 3. Install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5573 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5574 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5575 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5576 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5577 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5578 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5579 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5580 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5581 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5582 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5583 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5584 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5585 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5586 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5587 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5588 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5589 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5590 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5591 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5592 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5593 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5594 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5595 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5596 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5597 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5598 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5599 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5600 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5601 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5602 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5603 Oxygen Sensor: Connector Views Delphi Heated Oxygen Sensor (H02S) Bank 1 Sensor 2 (Delphi) Heated Oxygen Sensor (H02S) Bank 1 Sensor 1 (Delphi) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5604 Heated Oxygen Sensor (H02S) Bank 2 Sensor 1 (Delphi) Heated Oxygen Sensor (H02S) Bank 2 Sensor 2 (Delphi) Denso Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5605 Heated Oxygen Sensor (H02S) Bank 1 Sensor 2 (Denso) Heated Oxygen Sensor (H02S) Bank 1 Sensor 1 (Denso) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5606 Heated Oxygen Sensor (H02S) Bank 2 Sensor 1 (Denso) Heated Oxygen Sensor (H02S) Bank 2 Sensor 2 (Denso) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 5607 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSORS The main function of the pre-catalyst HO2S is to provide the PCM with exhaust stream information in order to maintain proper fueling to hold emissions within acceptable levels. These oxygen sensors are always located between the exhaust manifold and the 3-way Catalytic Converter (TWC). After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases. The PCM uses the signal voltage from the fuel control HO2S in a Closed Loop in order to adjust the fuel injector pulse width. While in a Closed Loop, the PCM can adjust fuel delivery in order to maintain an air to fuel ratio which allows the best combination of emission control and driveability. If the HO2S pigtail wiring, connector, or terminal are damaged, replace the entire HO2S assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must be provided with a clean air reference. This clean air reference is obtained by way of the HO2S wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference. Any attempt to repair the wires, connectors, or terminals could degrade HO2S performance. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5610 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5611 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5612 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5613 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5614 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5615 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 5616 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5623 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5624 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5625 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5626 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5627 Body Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5628 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5629 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5630 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5631 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5632 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5633 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5634 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5635 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5636 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5637 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5638 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5639 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5640 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5641 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5642 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5643 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5644 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5645 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5646 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5647 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5648 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5649 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5650 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5651 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5652 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5653 Body Control Module: Connector Views Body Control Module Connector (BCM) - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5654 Body Control Module (BCM) - C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5655 Body Control Module (BCM) - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5656 Body Control Module: Electrical Diagrams Controlled/Monitored Subsystem References Controlled/Monitored Subsystem References Body Control Module Schematics: Controlled/Monitored Subsystem References Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5657 Exterior Lighting Systems References Exterior Lighting Systems References Body Control Module Schematics: Exterior Lighting Systems References Interior Lighting Systems References Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5658 Interior Lighting Systems References Body Control Module Schematics: Interior Lighting Systems References Power, Ground and Serial Data Power, Ground and Serial Data Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5659 Body Control Module Schematics: Power, Ground And Serial Data Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures IMPORTANT: If any module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not properly configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: ^ The battery is fully charged. ^ The ignition switch is in the RUN position. ^ The DLC is accessible. ^ All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: ^ Inspect all BCM connections. ^ Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to the Theft Deterrent sub-system for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve History DTCs from all modules. 5. Clear all history DTCs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 5662 Body Control Module: Removal and Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable(s). 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the BCM from the sliding bracket. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 5663 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. 4. Install the knee bolster. 5. Connect the negative battery cable(s). 6. Reprogram the BCM. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations Electronic Throttle Control Module: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 5667 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 5668 Electronic Throttle Control Module: Diagrams Throttle Actuator Control (TAC) Module Connector C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 5669 Throttle Actuator Control (TAC) Module Connector C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 5670 Electronic Throttle Control Module: Description and Operation THROTTLE ACTUATOR CONTROL (TAC) MODULE Throttle Actuator Control (TAC) Module The TAC module is the control center for the electronic throttle system. The TAC module and the powertrain control module (PCM) communicate via a dedicated redundant serial data circuit. The TAC module and the PCM monitor the commanded throttle position and compare the commanded position to the actual throttle position. This is accomplished by monitoring the APP and the TP sensor. These 2 values must be within a calibrated value of each other. The TAC module also monitors each individual circuit of the TP sensor and the APP to verify proper operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 5671 Electronic Throttle Control Module: Service and Repair THROTTLE ACTUATOR CONTROL (TAC) MODULE REPLACEMENT REMOVAL PROCEDURE 1. Release the retainer tab from the left side of the throttle actuator control (TAC) module. 2. Slowly slide the TAC module out of the retaining bracket. 3. Disconnect the TAC module connectors from the TAC module. INSTALLATION PROCEDURE 1. Connect the TAC module connectors to the TAC module. 2. Slide the TAC module into the TAC module bracket. 3. Push the TAC module towards the bracket in order to snap the TAC module into the bracket. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 5680 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 5686 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 5691 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 5697 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5698 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5701 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5702 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5703 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5704 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5705 Engine Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5706 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5707 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5708 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5709 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5710 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5711 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5712 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5713 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5714 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5715 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5716 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5717 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5718 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5719 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5720 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5721 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5722 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5723 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5724 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5725 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5726 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 Powertrain Control Module (PCM) C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 Powertrain Control Module (PCM) C1 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 Powertrain Control Module (PCM) C2 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 Powertrain Control Module (PCM) C2 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5736 Powertrain Control Module (PCM) C2 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description Engine Control Module: Description and Operation Electronic Ignition (EI) System Description POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: ^ The Throttle Position (TP) Sensor ^ The Engine Coolant Temperature (ECT) Sensor ^ The Mass Airflow (MAF) sensor ^ The Intake Air Temperature (IAT) Sensor ^ The Vehicle Speed Sensor (VSS) ^ The transmission gear position or range information sensors ^ The Engine Knock Sensors (KS) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 5739 Engine Control Module: Description and Operation Powertrain Control Module (PCM) Description General Information The Powertrain Control Module (PCM) is designed to maintain exhaust emission levels while maintaining excellent driveability and fuel efficiency. The PCM controls the following operations: ^ The fuel control ^ The Ignition Control (IC) ^ The Knock Sensor (KS) system ^ The automatic transmission shift functions ^ The manual transmission ^ The cruise control enable, if equipped ^ The generator ^ The evaporative emissions (EVAP) purge ^ The A/C clutch control, if equipped ^ The secondary air injection (AIR), if equipped ^ The Exhaust Gas Recirculation (EGR) PCM Function The PCM supplies a buffered voltage to various sensors and switches. The PCM controls most components with electronic switches which complete a ground circuit when turned ON. Powertrain Control Module Powertrain Control Module The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is the control center of the vehicle. The PCM controls the following: ^ The fuel metering system ^ The transmission shifting ^ The ignition timing ^ The on-board diagnostics for powertrain functions The PCM constantly monitors the information from various sensors and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic functions for those systems. The PCM can recognize operational problems and alert the driver through the Malfunction Indicator Lamp (MIL) when a malfunction has occurred. When a malfunction is detected, the PCM stores a Diagnostic Trouble Code (DTC) which helps to identify problem areas. This is done to aid the technician in making repairs. The PCM supplies either 5.0 or 12.0 volts to power various sensors and switches. This is done through resistances in the PCM. The resistance is so high in value that a test lamp does not illuminate when connected to the circuit. In some cases, even an ordinary shop voltmeter does not give an accurate reading because the voltmeters resistance is too low. Therefore, a DMM with a minimum of 10 megaohms input impedance is required to ensure accurate voltage readings. The PCM controls output circuits such as the fuel injectors, the Idle Air Control (IAC), the cooling fan relays, etc. by controlling the ground or the power feed circuit through transistors or a device called an output driver module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 5740 Torque Management Torque management is a function of the PCM that reduces engine power under certain conditions. Torque management is performed for the following reasons: 1. To prevent over-stressing the powertrain and driveline components 2. To prevent damage to the vehicle during certain abusive maneuvers 3. To reduce engine speed when the IAC is out of the normal operating range The PCM monitors the following sensors and engine parameters in order to calculate engine output torque: ^ The air/fuel ratio ^ The Mass Air Flow (MAF) sensor ^ The Manifold Absolute Pressure (MAP) Sensor ^ The Intake Air Temperature (IAT) Sensor ^ The spark advance ^ The engine speed ^ The Engine Coolant Temperature (ECT) Sensor ^ The A/C clutch status The PCM monitors the torque converter status, the transmission gear ratio, and the engine speed in order to determine if torque reduction is required. The PCM retards the spark as appropriate to reduce engine torque output if torque reduction is required. The PCM also shuts OFF the fuel to certain injectors in order to reduce the engine power in the case of an abusive maneuver. The following are instances when engine power reduction is likely to be experienced: ^ During transmission upshifts and downshifts ^ During heavy acceleration from a standing start ^ When the clutch pedal is released too quick under a heavy load, 6.0L only ^ When one set of drive axles looses traction while the other set of drive axles are not moving, 4 Wheel Drive only and in 4WD low ^ If the IAC is out of the normal operating range, except 6.0L ^ When the driver is performing harsh or abusive maneuvers such as shifting into gear at high throttle angles or shifting the transmission from reverse to drive to create a rocking motion The driver is unlikely to notice the torque management actions in the first 2 instances. The engine power output is moderate at full throttle in the other cases. The PCM calculates the amount of spark retard necessary to reduce the engine power by the desired amount. The PCM disables the fuel injectors for cylinders 1, 4, 6, and 7 in the case of an abusive maneuver. Basic Knowledge Required Without a basic knowledge of electricity, you will have difficulty using the diagnostic procedures. You should understand the basic theory of electricity and know the meaning of voltage-volts, current-amps, and resistance-ohms. You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. PCM Service Precautions The PCM is designed to withstand normal current draws associated with vehicle operations. Avoid overloading any circuit. When testing for opens or shorts, do not ground any of the PCM circuits unless instructed. When testing for opens or shorts, do not apply voltage to any of the PCM circuits unless instructed. Only test these circuits with a DMM while the PCM connectors remain connected. Engine Controls Information The driveability and emissions information describes the function and operation of the powertrain control module (PCM). The engine controls Information contains the following: ^ Component locations ^ Wiring diagrams ^ PCM terminal end view and terminal definitions ^ Diagnostic System Check-Computers and Controls Systems ^ Diagnostic trouble code (DTC) tables The component system includes the following items: ^ Component and circuit description ^ On-vehicle service for each sub-system ^ Functional checks and diagnostic tables The DTCs also contain diagnostic support information containing circuit diagrams, circuit or system information, and helpful diagnostic information. System Status and Drive Cycle For Inspection/Maintenance The System Status selection is included in the scan tool System Info menu. Several states require that the I/M (OBD II system) pass on-board tests for the major diagnostics prior to having a vehicle emission inspection. This is Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 5741 also a requirement to renew license plates in some areas. Using a scan tool, the technician can observe the System Status, complete or not complete, in order to verify that the vehicle meets the criteria to comply with local area requirements. Using the System Status display, any of the following systems or combination of systems may be monitored for I/M Readiness: ^ The catalyst ^ The Evaporative Emission (EVAP) system ^ The Heated Oxygen Sensors (HO2S) ^ The HO2S heater ^ The Exhaust Gas Recirculation (EGR) system ^ The secondary air injection (AIR) system IMPORTANT: The System Status display indicates only whether or not the test has been completed. The System Status display does not necessarily mean that the test has passed. If a Failed Last Test indication is present for a DTC associated with one of the above systems, diagnosis and repair is necessary in order to meet the I/M requirement. Verify that the vehicle passes all of the diagnostic tests associated with the displayed System Status prior to returning the vehicle to the customer. Refer to the Typical Drive Cycle table, more than one drive cycle may be needed, to use as a guide to complete the I/M System Status tests. Typical Drive Cycle Following a DTC info clear, System Status clears for one or all of these systems. Following a battery disconnect or a PCM replacement, all System Status information clears. Primary System Based Diagnostics There are primary system-based diagnostics which evaluate the system operation and their effect on vehicle emissions. The primary system-based diagnostics are listed below, with a brief description of the diagnostic functionality. Oxygen Sensor Diagnosis Diagnose the fuel control heated oxygen sensors (HO2S) for the following conditions: ^ Heater performance, heater current monitor ^ Response switches, number or switches R/L or L/R ^ Response time, time to switch R/L or L/R ^ Inactive signal, output steady at bias voltage - approximately 450 mV ^ Signal fixed high ^ Signal fixed low Diagnose the catalyst monitor HO2S for the following functions: ^ Heater performance, heater current monitor ^ Signal fixed low ^ Signal fixed high ^ Inactive sensor Heated Oxygen Sensors The main function of the pre-catalyst HO2S is to provide the PCM with exhaust stream information in order to maintain proper fueling to hold emissions within acceptable levels. These oxygen sensors are always located between the exhaust manifold and the 3-way Catalytic Converter (TWC). After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases. The PCM uses the signal voltage from the fuel control HO2S in a Closed Loop in order to adjust the fuel injector pulse width. While in a Closed Loop, the PCM can adjust fuel delivery in order to maintain an air to fuel ratio which allows the best combination of emission control and driveability. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 5742 If the HO2S pigtail wiring, connector, or terminal are damaged, replace the entire HO2S assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must be provided with a clean air reference. This clean air reference is obtained by way of the HO2S wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference. Any attempt to repair the wires, connectors, or terminals could degrade HO2S performance. Catalyst Monitor Heated Oxygen Sensors In order to control emissions of HydroCarbons (HC), Carbon Monoxide (CO), and Oxides Of Nitrogen (NOx), the system uses a TWC. The catalyst promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting the HC and CO into harmless water vapor and carbon dioxide. The catalyst also converts NOx to nitrogen. Catalyst monitor HO2S, post-catalyst HO2S, are always located downstream of the catalytic converter. The PCM has the ability to monitor this process using the post catalyst HO2S. The pre-sensors produce an output signal which indicates the amount of oxygen present in the exhaust gas entering the TWC. The post sensor produces an output signal which indicates the oxygen storage capacity of the catalyst. This in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the pre-HO2S signal is far more active than that produced by the post-HO2S. In addition to catalyst monitoring, the post-HO2S has a limited role in controlling fuel delivery. If the post-HO2S signal indicates a high or low oxygen content for an extended period of time while in a Closed Loop, the PCM adjusts the fuel delivery slightly in order to compensate. Catalyst Monitor Diagnostic Operation The catalyst monitor diagnostic measures oxygen storage capacity of the catalyst converter. In order to do this, the HO2S are installed before and after the TWC. Voltage variations between the sensors allow the PCM to determine the catalyst emission performance. As a catalyst becomes less effective in promoting chemical reactions, the catalysts capacity to store and release oxygen generally degrades. The catalyst monitor diagnostic is based on a correlation between conversion efficiency and oxygen storage capacity. A good catalyst, e.g. 95 percent hydrocarbon conversion efficiency, shows a relatively flat output voltage on the post-catalyst HO2S. A degraded catalyst, 65 percent hydrocarbon conversion, shows a greatly increased activity in output voltage from the post catalyst HO2S. The post-catalyst HO2S is used to measure the oxygen storage and release capacity of the catalyst. A high oxygen storage capacity indicates a good catalyst. Low oxygen storage capacity indicates a failing catalyst. The TWC and the HO2S must be at operating temperature in order to achieve correct oxygen sensor voltages like those shown in the post-catalyst HO2S outputs graphic. The catalyst monitor diagnostic is sensitive to the following conditions: ^ Exhaust leaks ^ HO2S contamination ^ Alternative fuels Exhaust system leaks may cause the following: ^ Prevent a degraded catalyst from failing the diagnostic ^ Cause a false failure for a normally functioning catalyst ^ Prevent the diagnostic from running Some of the contaminants that may be encountered are phosphorus, lead, silica, and sulfur. The presence of these contaminants prevent the TWC diagnostic from functioning properly. Three-Way Catalyst Oxygen Storage Capacity Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 5743 Three-Way Catalyst Oxygen Storage Capacity The PCM must monitor the TWC system for efficiency. In order to accomplish this, the PCM monitors the pre-catalyst and post-catalyst HO2S. When the TWC is operating properly, the post-catalyst (2) HO2S shows significantly less activity than the pre-catalyst (1) HO2S. The TWC stores oxygen during the normal reduction and oxidation process. The TWC releases oxygen during the normal reduction and oxidation process. The PCM calculates the oxygen storage capacity using the difference between the pre-catalyst and post-catalyst HO2S voltage levels. Whenever the sensor activity of the post-catalyst (2) HO2S nears the sensor activity of the pre-catalyst (1) HO2S, the catalysts efficiency is degraded. Aftermarket HO2S characteristics may be different from the original equipment manufacturer sensor. This may lead to a false pass or a false fail of the catalyst monitor diagnostic. Similarly, if an aftermarket catalyst does not contain the same amount of precious metal content as the original part, the correlation between oxygen storage and conversion efficiency may be altered enough to set a false DTC. Misfire Monitor Diagnostic Operation The misfire monitor diagnostic is based on crankshaft rotational velocity, aka reference period, variations. The PCM determines crankshaft rotational velocity using the Crankshaft Position (CKP) Sensor and Camshaft Position (CMP) Sensor. When a cylinder misfires, the crankshaft slows down momentarily. By monitoring the crankshaft and CMP sensor signals, the PCM can calculate when a misfire occurs. For a non-catalyst damaging misfire, the diagnostic is required to monitor a misfire present for between 1,000-3,200 engine revolutions. For catalyst damage misfire, the diagnostic responds to the misfire within 200 engine revolutions Rough roads may cause false misfire detection. A rough road applies sudden torque variations to the drive wheels and drivetrain. This torque can intermittently decrease the crankshaft rotational velocity. The Antilock Braking (ABS) System detects uneven speed between the vehicles wheels and sends data via the serial data bus to the PCM to disable the misfire monitor until the rough road is no longer detected. On automatic transmission equipped vehicles, the Torque Converter Clutch (TCC) disables whenever a misfire is detected. Disabling the TCC isolates the engine from the rest of the drive line and minimizes the affect of the drive wheel inputs on crankshaft rotation. When the TCC has disabled as a result of misfire detection, the TCC is re-enabled after approximately 3,200 engine revolutions if no misfire is detected. The TCC remains disabled whenever the misfire is detected, with or without a DTC set. This allows the misfire diagnostic to reevaluate the system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 5744 Whenever a cylinder misfires, the misfire diagnostic counts the misfire and notes the crankshaft position at the time the misfire occurred. A current and a history misfire counter is maintained for each cylinder. The misfire current counters, Misfire Cur #1-8, indicate the number of firing events out of the last 200 cylinder firing events which were misfires. The misfire current counters displays real time data without a misfire DTC stored. The misfire history counters, Misfire Hist #1-8, indicate the total number of cylinder firing events which were misfires. The misfire history counters display 0 until the misfire diagnostic has failed and a DTC P0300 is set. Once the misfire DTC sets, the misfire history counters will be updated every 200 cylinder firing events. The Misfire counters graphic illustrates how these misfire counters are maintained. When crankshaft rotation is erratic, the PCM detects a misfire condition. Because of this erratic condition, the data that is collected by the diagnostic can sometimes incorrectly identify which cylinder is misfiring. The Misfire Counters graphic shows there are misfires counted from more than one cylinder. Cylinder #1 has the majority of counted misfires. In this case, the misfire counters would identify cylinder #1 as the misfiring cylinder. The misfires in the other counters were just background noise caused by the erratic rotation of the crankshaft. If the number of accumulated misfires is sufficient for the diagnostic to identify a true misfire, the diagnostic will set DTC P0300-Misfire Detected. The illustration depicts an accumulation in the history buffers. If two cylinders in sequential tiring order are both misfiring, the first misfiring cylinder will accumulate misfires in the cylinder buffer, but the second misfiring cylinder will not. This is because the PCM compares a misfiring cylinder with the cylinder 90 degrees prior to that cylinder in the firing order. Therefore the PCM would be comparing crankshaft speed of the second misfiring cylinder to an already suspect cylinder. The PCM however, will be able to detect both misfiring cylinders after the engine exceeds 2,000 RPM. This is because the PCM then starts to compare misfires to the opposing cylinder rather than the previous cylinder in the firing order. Use Techline equipment to monitor the misfire counter data on applicable vehicles. Knowing which specific cylinders misfire can lead to the root cause. Using the information in the misfire counters identifies which cylinders are misfiring. If the counters indicate cylinders number 1 and 4 misfired, look for a circuit or component common to both cylinders. The misfire diagnostic may indicate a fault due to a temporary fault not necessarily caused by a vehicle emission system malfunction. Examples include the following items: ^ Contaminated fuel Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Ignition (EI) System Description > Page 5745 ^ Running out of fuel ^ Fuel fouled spark plugs ^ Basic engine fault Fuel Trim System Operation The fuel trim system monitors the averages of short-term and long-term fuel trim values. If these fuel trim values stay at the individual limits for a calibrated period of time, a malfunction is indicated. The fuel trim diagnostic compares the average of short and long-term fuel trim values. If either value is within the thresholds, a pass is recorded. If either value is outside the thresholds, a rich or lean fuel trim DTC will set. Comprehensive Component Monitor Diagnostic Comprehensive component monitoring diagnostics are required to monitor emissions-related input and output powertrain components. Input Components The PCM monitors the input components for circuit continuity and out-of-range values. This includes performance checking. Performance checking refers to indicating a fault when the signal from a sensor does not seem reasonable, such as a Throttle Position (TP) sensor that indicates high throttle position at low engine loads or manifold Absolute Pressure (MAP) Voltage. The input components may include, but are not limited to, the following sensors: ^ The Vehicle Speed (VSS) Sensor ^ The Mass Air Flow (MAF) Sensor ^ The Intake Air Temperature (IAT) Sensor ^ The Crankshaft Position (CKP) Sensor ^ The Knock Sensor (KS) ^ The Throttle Position (TP) Sensor ^ The Engine Coolant Temperature (ECT) Sensor ^ The Camshaft Position (CMP) Sensor ^ The Manifold Absolute Pressure (MAP) Sensor In addition to the circuit continuity and rationality check, the engine coolant temperature (ECT) sensor is monitored for the sensors ability to achieve a steady state temperature to enable Closed Loop fuel control. Output Components Diagnose the output components for the proper response to PCM commands. Components where functional monitoring is not feasible will be monitored for circuit continuity and out-of-range values if applicable. Output components to be monitored include, but are not limited to, the following circuits: ^ The Idle Air Control (IAC) Motor ^ The Evaporative Emission (EVAP) System ^ The electronic transmission controls ^ The A/C relay, if equipped ^ The VSS output ^ The Malfunction Indicator Lamp (MIL) Control ^ The cruise control enable, if equipped Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) Engine Control Module: Service and Repair Powertrain Control Module (PCM) Programming (Off-board) BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: ^ DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. ^ The Off-Board Programming is used in situations where a control module must be programmed without having the vehicle present. The Off-Board Programming Adapter must be used to perform the Off-Board Programming procedure. The adapter allows the control module to power up and allows the Tech 2 to communicate with the control module. ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. Ensure that all connections are secure at the following locations: ^ The Off-Board Programming Adapter ^ The Tech 2 ^ The control module ^ The Techline terminal OFF-BOARD PROGRAMMING 1. Obtain the VIN of the vehicle for which the control module is being programmed. 2. With the Techline terminal, select Service Programming. 3. Select Tech 2, Reprogram ECU, and Off-Board Programming Adapter as the ECU location. 4. Connect the control module, Off-Board Programming Adapter, and the Tech 2 as described on the Techline terminal. Ensure you use the correct harness connector from the Off-Board Programming Adapter kit. 5. With the Tech 2, select Service Programming Request Information function. The Tech 2 communicates with the control module and receives the access code. 6. With the Tech 2, exit the Service Programming Request Information. 7. Disconnect the Tech 2 from the Off-Board Programming Adapter. 8. Connect the Tech 2 to the Techline terminal. 9. Turn ON the Tech 2. 10. With the Techline terminal, enter the VIN of the vehicle that will be receiving the control module. 11. The Techline terminal will display the message, attaching to database. 12. Identify what type of programming that you are performing. 13. Select the appropriate calibration file. 14. Ensure all connections are secure. 15. The Techline terminal displays a summary screen that summarizes your selections. After confirming you choices, the Techline terminal automatically loads the calibration files to the Tech 2. 16. After the download is complete, turn OFF the Tech 2. 17. Disconnect the Tech 2 from the Techline terminal. 18. Connect the Tech 2 to the Off-Board Programming Adapter. 19. With the Tech 2, select Service Programming. IMPORTANT: DO NOT turn OFF the Off-Board Programming Adapter if the programming procedure is interrupted or unsuccessful. Ensure the control module and the Off-Board Programming Adapter connections are secure and the Techline operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. 20. With the Tech 2, select Program. 21. After the download is complete, exit Service Programming. 22. Turn OFF the Off-Board Programming Adapter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 5748 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Programming (On-Board) BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customers concern. Ensure the following conditions are met before programming a control module: ^ Vehicle system voltage There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicle's battery. ^ Twilight sentinel ^ Interior lights ^ Daytime running lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. Refer to the Owners manual. ^ HVAC systems ^ Cooling System fans, etc. ^ The ignition is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. ^ All tool connections are secure. RS-232 - The connection at the DLC is secure. - Voltage supply circuits ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. REMOTE PROGRAMMING 1. Turn OFF the ignition. 2. Install the Tech 2 to the data link connector (DLC). 3. Turn ON the ignition, with the engine OFF. 4. Turn OFF all vehicle accessories. 5. With the Tech 2, select Service Programming. 6. Identify vehicle information as requested by the Tech 2. 7. Select the type of module you are programming. 8. Select the type of programming to be performed. 9. Verify the displayed VIN with the vehicle VIN. If the displayed VIN does not match the actual VIN, write down the actual VIN and correct the VIN at the Techline terminal. 10. When complete, Exit Service Programming. 11. Turn OFF the Tech 2 and disconnect the Tech 2 from the vehicle. 12. Turn OFF the ignition. 13. Connect the Tech 2 to the Techline terminal. 14. Select Service Programming. 15. Select Tech 2 as the tool you are using. 16. Select the type of programming to be performed. 17. Verify the displayed VIN with the vehicle VIN. Correct the VIN as necessary. 18. Select the type of module you are programming. 19. Identify what type of programming that you are performing. ^ Normal-This type of programming is for updating an existing calibration or programming a new controller. ^ Vehicle configuration index (VCI)-This selection is used if the vehicle VIN is unavailable or not recognized by the Techline terminal. Observe, you will need to contact the Techline Customer Support center to use this option. ^ Reconfigure-This is to reconfigure a vehicle, such as tire size and axle ratio changes. 20. Select the appropriate calibration file. 21. Ensure all connections are secure. 22. Select Reprog to initiate the download of the new calibration to the Tech 2. 23. After the download is complete, turn OFF the Tech 2. 24. Disconnect the Tech 2 from the Techline terminal. 25. Install the Tech 2 to the data link connector (DLC). 26. Turn ON the Tech 2. 27. Turn ON the ignition, with the engine OFF. 28. Select Service Programming. IMPORTANT: DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all the PCM and DLC Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 5749 connections are secure and the Techline(TM) operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. Refer to Powertrain Control Module (PCM) Replacement. 29. Select Program. 30. After the download is complete, EXIT Service Programming. 31. Turn OFF the ignition for 30 seconds. 32. Turn OFF the Tech 2. 33. If a control module is replaced the following service procedures must be performed: ^ CKP System Variation Learn Procedure ^ Inspection/Maintenance (I/M) Complete System Set Procedure ^ Programming Theft Deterrent System Components PROGRAMMING VERIFICATION 1. With a scan tool, clear the DTCs. 2. Attempt to start the engine. 3. Repeat the Service Programming procedure if the engine does not start or operates poorly. Perform the following procedures before programming the PCM: ^ Ensure the control module and DLC connections are OK. ^ Ensure the Techline operating software is up to date. ^ Ensure the calibration part number is correct for the vehicle. 4. Attempt to program the control module. If the control module still cannot be programmed properly, replace the control module. Refer to Powertrain Control Module (PCM) Replacement. You must program the replacement control module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 5750 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Replacement Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. ^ Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. ^ The replacement PCM must be programmed Removal Procedure 1. Release the PCM cover mounting holes (1,5) away from the mounting tabs on the PCM mounting bracket. 2. Release the PCM cover (8) from the mounting bracket. 3. Remove the PCM cover. NOTE: ^ Refer to PCM and ESD Notice in Service Precautions. ^ In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 4. Disconnect the PCM harness connectors (6). 5. Release the spring latch (2) from the PCM. 6. Release the PCM mounting tabs (3) from the PCM. 7. Remove the PCM (4) from the engine compartment. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 5751 1. Install the PCM (4) to the PCM mounting bracket (7) ensuring that the mounting tabs (3) are engaged. 2. Secure the spring latch (2) to the PCM. NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the PCM connectors (6) to the PCM (4). Tighten Tighten the PCM connector end fasteners to 8 N.m (71 lb in). 4. Install the PCM cover (8) to the PCM mounting bracket (7), ensuring the mounting tabs on the PCM mounting bracket are engaged into the mounting holes in the PCM cover. 5. If a new PCM is being installed, program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 5752 Engine Control Module: Service and Repair Service Programming System (SPS) The Service Programming System (SPS) allows a technician to program a control module through the Data Link Connector (DLC). The information transfer circuit that is used at the DLC is the same serial data circuit used by the scan tool for retrieving Diagnostic Trouble Codes (DTCs), displaying data, clearing DTCs, etc. This procedure offers the ability to install software/calibrations matched to a particular vehicle. Most control modules have 2 types of memory. The software/calibrations reside in the flash memory. The two types of memory are listed below: ^ Electrically Erasable Programmable Read Only Memory (EEPROM) This type of memory allows selected portions of memory to be programmed while other portions remain unchanged. Certain learned values reside in the EEPROM, such as: ^ The Vehicle Identification Number (VIN) ^ The crankshaft variation learned position ^ The software/calibrations identification numbers ^ The control module security information ^ Flash Read Only Memory - Flash Memory ^ Flash memory has increased memory storage capacity. During programming, all information within this type of memory is erased, and then replaced with entirely new information. Service Programming Methods The 4 methods of programming a control module and the proper tools for each method are as follows: ^ Remote Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle ^ Pass Thru Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle. ^ Off-Board Remote Programming, vehicle NOT available: The Tech 2 or other scan tool, Off-board Programming Adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle ^ Off-Board Pass Thru Programming - The Tech 2 or other scan tool, off-board programming adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software-The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle Before Programming A Control Module IMPORTANT: DO NOT program an existing control module with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A control module should only be programmed when the following occurs: ^ When a service procedure instructs you to replace the control module. The service part control module does not contain operating software or calibrations. ^ General Motors Corporation releases an updated software/calibration package. Ensure that the following conditions are met before programming a control module: ^ Vehicle system voltage: There are no charging system concerns. All charging system concerns must be repaired before programming a control module. - The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged before programming the control module. - A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or disable systems such as: ^ Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. ^ Heating, Ventilation, And Air Conditioning (HVAC) systems ^ Engine cooling fans, etc ^ The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. ^ All tool connections are secure: The RS-232 cable - The connection at the DLC - The voltage supply circuits Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Programming (Off-board) > Page 5753 - The OBPA ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. ^ If you are performing the pass-through programming procedure using a notebook computer without the power cord, ensure that the internal battery is fully charged. After Programming a Control Module The powertrain may operate slightly different after a control module software/calibration update. Operating the powertrain through various driving conditions allows the control module to re-learn certain values. The control module must re-learn the following after a software/calibration update: ^ Fuel trim correction ^ Idle Air Control (IAC) learned position ^ Automatic transmission shift adapts Other learned values only re-learn by performing a service procedure. If a control module is replaced the following service procedures may need to be performed: ^ The crankshaft variation learn procedure ^ The engine oil life reset procedure ^ The idle learn procedure ^ The inspection/maintenance complete system set procedure ^ The vehicle theft deterrent password learn procedure ^ The Throttle Position (TP) sensor learn procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5758 Accelerator Pedal Position (APP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5759 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position (APP) Sensor The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 3 individual accelerator pedal position sensors within one housing. Three separate signal, low reference, and 5-volt reference circuits are used to connect the APP and the TAC module. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 1.0 volt at 0 pedal travel to above 2.0 volts at 100 percent pedal travel. APP sensor 2 voltage should decrease from above 4.0 volts at 0 pedal travel to below 2.9 volts at 100 percent pedal travel. APP sensor 3 voltage should decrease from above 3.8 volts at 0 percent pedal travel to below 3.1 volts at 100 percent pedal travel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5760 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the left instrument panel (IP) lower closeout insulator panel. 2. Disconnect the accelerator pedal position (APP) sensor harness connector. Remove the accelerator pedal mounting bolts. 3. Remove the APP assembly. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5761 1. Install the APP assembly to the steering column support bracket. NOTE: Refer to the Fastener Notice in Service Precautions. IMPORTANT: Always use a torque wrench in order to obtain the proper torque. 2. Install the accelerator pedal mounting bolts. Tighten Tighten the accelerator pedal mounting bolts to 20 N.m (15 lb ft). 3. Connect the APP sensor harness connector. 4. Verify that the vehicle meets the following conditions: ^ The vehicle is not in a Reduced Engine Power mode. ^ The ignition is ON. ^ The engine is OFF. 5. Connect a scan tool in order to test for a proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Inspect the carpet fit under the accelerator pedal. 8. Install the left IP lower closeout insulator panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5767 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5768 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5770 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5771 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5775 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5776 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5777 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5778 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5779 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5780 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5781 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5782 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5783 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5784 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5785 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5786 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5787 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5788 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5789 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5790 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5791 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5792 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5793 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5794 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5795 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5796 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5797 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 5798 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Take care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. Do not drop or roughly handle the MAF/IAT sensor. 1. Remove air intake resonator. 2. Disconnect the MAF/IAT sensor electrical connector. 3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 5799 2. Install the MAF/IAT sensor on to the air cleaner housing. 3. Tighten the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Connect the MAF/IAT electrical connector. 5. Install air intake resonator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5805 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5809 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5810 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5813 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5814 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5815 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5816 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5817 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5818 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5819 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5825 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5826 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5827 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5828 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5829 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5830 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5831 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5832 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5833 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5834 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5835 Camshaft Position (CMP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 5836 Camshaft Position Sensor: Description and Operation The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 5837 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. Camshaft Position Sensor (CMP) 1. Remove the engine sight shield, as necessary. 2. Disconnect the CMP sensor electrical connector. 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor. INSTALLATION PROCEDURE Camshaft Position Sensor (CMP) 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CMP sensor electrical connector. 4. Install the engine sight shield, as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5841 Engine Coolant Temperature (ECT) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5842 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.. 3. Drain the cooling system below the level of the ECT sensor. Refer to Draining and Filling Cooling System in Cooling System. 4. Lower the vehicle. 5. Disconnect the electrical connector from the engine coolant temperature (ECT) sensor. 6. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: ^ Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. ^ Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5843 1. Coat the ECT sensor threads with sealer GM P/N 12346004 or the equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5849 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5850 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5851 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5852 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5853 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5854 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5855 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5856 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5857 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5858 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5859 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5860 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5861 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5862 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5863 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5864 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5865 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5866 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5867 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5868 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5869 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5870 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5871 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5872 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5873 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5874 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5875 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5876 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5877 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5878 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5879 Crankshaft Position (CKP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 5880 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at Top Dead Center (TDC). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module (PCM) for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. Observe the fuel cut-off for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: ^ Block the drive wheels. ^ Apply the vehicles parking brake. ^ Cycle the ignition from OFF to ON. ^ Apply and hold the brake pedal. ^ Start and idle the engine. ^ Turn OFF the AC. ^ Place the vehicle's transmission in Park (A/T) or Neutral (M/T). ^ The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. With the scan tool, enable the CKP system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-off is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine Mechanical. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5883 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure when the crankshaft position sensor is removed or replaced. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the starter. 4. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5884 5. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 6. Remove the CKP sensor retaining bolt. 7. Remove the CKP sensor. INSTALLATION PROCEDURE Crankshaft Position Sensor (CKP) 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor retaining fastener. Tighten Tighten the bolt to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5885 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5889 Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The Powertrain Control Module (PCM) sends the fuel level information via the class 2 circuit to the Instrument Panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5890 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the retaining clip (6) from the fuel level sensor connector. 4. Disconnect the electrical connector (7) from under the fuel sender cover. 5. Remove the sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip (4). 3. Connect the electrical connector (7) to the fuel level sensor. 4. Connect the retaining clip (6) to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 5894 Fuel Tank Pressure (FTP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 5895 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 5896 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Remove the fuel pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel pressure sensor (1). 2. Install the fuel tank. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 5900 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 5901 Intake Air Temperature Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Take care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. Do not drop or roughly handle the MAF/IAT sensor. 1. Remove air intake resonator. 2. Disconnect the MAF/IAT sensor electrical connector. 3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 5902 2. Install the MAF/IAT sensor on to the air cleaner housing. 3. Tighten the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Connect the MAF/IAT electrical connector. 5. Install air intake resonator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set Knock Sensor: Customer Interest Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-023A Date: June, 2002 TECHNICAL Subject: Audible Spark Knock (Detonation), MIL Illuminated, DTC P0332 Set (Replace Rear Bank Knock Sensor and RTV Area Around Sensor) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird with 5.7L Engine (VIN G - RPO LS1) 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalance 1999-2002 GMC Sierra, Yukon, Yukon XL 2002 Cadillac Escalade, Escalade EXT with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, N, U - RPOS LR4, LM7, L59, L09, L04) This bulletin is being revised to add Cadillac Escalade and Cadillac Escalade EXT to the Models. Please discard Corporate Bulletin Number 02-06-04-023 (Section 6 - Engine/Propulsion System). Condition Some customers may comment on a mild to severe engine ping (commonly referred to as spark knock), usually worse during acceleration and/or an illuminated MIL. Upon investigation, the technician may find DTC P0332 set. Cause This condition may be the result of corrosion of the rear bank knock sensor due to water intrusion into the sensor cavity. This condition is more apparent on vehicles in which customers frequently wash the engine compartment. Correction Replace the rear bank knock sensor and build a dam (wall) around the sensor using RTV to divert water away from the sensor. Use the procedure and part number listed. 1. Remove the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. 2. Remove the wiring harness assembly from the knock sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 5911 3. Remove the rear bank knock sensor. 4. Install the new rear bank knock sensor. Tighten Tighten the knock sensor to 20 N.m (15 lb ft). 5. Install the wiring harness assembly to the knock sensor. 6. Apply a bead of RTV silicone sealant approximately 9 mm (3/8 in) wide and 6 mm (1/4 in) high along the outside edge of the ridge on the engine block valley cover around the rear bank knock sensor. DO NOT form a complete circle. Leave the rear section open as shown. 7. From the underside of the intake manifold, completely remove the rear intake manifold seal (foam material). 8. Install the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 5912 For vehicles repaired under warranty, use the table as shown DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set Knock Sensor: All Technical Service Bulletins Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-023A Date: June, 2002 TECHNICAL Subject: Audible Spark Knock (Detonation), MIL Illuminated, DTC P0332 Set (Replace Rear Bank Knock Sensor and RTV Area Around Sensor) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird with 5.7L Engine (VIN G - RPO LS1) 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalance 1999-2002 GMC Sierra, Yukon, Yukon XL 2002 Cadillac Escalade, Escalade EXT with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, N, U - RPOS LR4, LM7, L59, L09, L04) This bulletin is being revised to add Cadillac Escalade and Cadillac Escalade EXT to the Models. Please discard Corporate Bulletin Number 02-06-04-023 (Section 6 - Engine/Propulsion System). Condition Some customers may comment on a mild to severe engine ping (commonly referred to as spark knock), usually worse during acceleration and/or an illuminated MIL. Upon investigation, the technician may find DTC P0332 set. Cause This condition may be the result of corrosion of the rear bank knock sensor due to water intrusion into the sensor cavity. This condition is more apparent on vehicles in which customers frequently wash the engine compartment. Correction Replace the rear bank knock sensor and build a dam (wall) around the sensor using RTV to divert water away from the sensor. Use the procedure and part number listed. 1. Remove the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. 2. Remove the wiring harness assembly from the knock sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 5918 3. Remove the rear bank knock sensor. 4. Install the new rear bank knock sensor. Tighten Tighten the knock sensor to 20 N.m (15 lb ft). 5. Install the wiring harness assembly to the knock sensor. 6. Apply a bead of RTV silicone sealant approximately 9 mm (3/8 in) wide and 6 mm (1/4 in) high along the outside edge of the ridge on the engine block valley cover around the rear bank knock sensor. DO NOT form a complete circle. Leave the rear section open as shown. 7. From the underside of the intake manifold, completely remove the rear intake manifold seal (foam material). 8. Install the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 5919 For vehicles repaired under warranty, use the table as shown DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Page 5920 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5923 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5924 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5925 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5926 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5927 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5928 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5929 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5930 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5931 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5932 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5933 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5934 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5935 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5936 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5937 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5938 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5939 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5940 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5941 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5942 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5943 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5944 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5945 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5946 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5947 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5948 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5949 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5950 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5951 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5952 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5953 Knock Sensor (KS) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 5954 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: ^ The broadband single wire sensor ^ The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: ^ All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. ^ The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near Top Dead Center (TDC) of the firing stroke. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 5955 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Remove the knock sensor wiring harness assembly. 3. Remove the knock sensor (KS). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 5956 1. Install the knock sensor. Tighten Torque the sensor to 20 N.m (15 lb ft). 2. Install the knock sensor wiring harness assembly. 3. Install the intake manifold. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 5960 Manifold Absolute Pressure (MAP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 5961 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector. 3. Remove the MAP sensor (1) from the intake manifold. INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 5962 1. Install the MAP sensor (1). Push the MAP sensor down in order to engage the sensor into the retainer. 2. Connect the MAP sensor electrical connector. 3. Install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Diagrams Engine Oil Level Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5971 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5972 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5973 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5974 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5975 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5976 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5977 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5978 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5979 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5980 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5981 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5982 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5983 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5984 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5985 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5986 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5987 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5988 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5989 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5990 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5991 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5992 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5993 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5994 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5995 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5996 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5997 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5998 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5999 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6000 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6001 Oxygen Sensor: Connector Views Delphi Heated Oxygen Sensor (H02S) Bank 1 Sensor 2 (Delphi) Heated Oxygen Sensor (H02S) Bank 1 Sensor 1 (Delphi) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6002 Heated Oxygen Sensor (H02S) Bank 2 Sensor 1 (Delphi) Heated Oxygen Sensor (H02S) Bank 2 Sensor 2 (Delphi) Denso Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6003 Heated Oxygen Sensor (H02S) Bank 1 Sensor 2 (Denso) Heated Oxygen Sensor (H02S) Bank 1 Sensor 1 (Denso) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6004 Heated Oxygen Sensor (H02S) Bank 2 Sensor 1 (Denso) Heated Oxygen Sensor (H02S) Bank 2 Sensor 2 (Denso) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 6005 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSORS The main function of the pre-catalyst HO2S is to provide the PCM with exhaust stream information in order to maintain proper fueling to hold emissions within acceptable levels. These oxygen sensors are always located between the exhaust manifold and the 3-way Catalytic Converter (TWC). After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases. The PCM uses the signal voltage from the fuel control HO2S in a Closed Loop in order to adjust the fuel injector pulse width. While in a Closed Loop, the PCM can adjust fuel delivery in order to maintain an air to fuel ratio which allows the best combination of emission control and driveability. If the HO2S pigtail wiring, connector, or terminal are damaged, replace the entire HO2S assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must be provided with a clean air reference. This clean air reference is obtained by way of the HO2S wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference. Any attempt to repair the wires, connectors, or terminals could degrade HO2S performance. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 6008 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 6009 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 6010 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 6011 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 6012 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 6013 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 6014 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6020 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6021 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6022 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6023 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6024 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6025 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6026 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6027 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6028 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6029 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6030 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6031 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6032 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6033 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6034 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6035 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6036 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6037 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6038 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6039 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6040 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6041 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6042 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6043 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6044 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6045 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6046 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6047 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6048 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6049 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6050 Throttle Position Sensor: Connector Views Throttle Position (TP) Sensor Throttle Position (TP) Sensor (Dual Track) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 6051 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to the Battery Disconnect Caution in Service Precautions. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result. IMPORTANT: If the vehicle is equipped with electronic throttle control (ETC) the throttle position (TP) sensor is NOT serviceable. The throttle body and TP sensor MUST be serviced as a complete assembly. 1. Disconnect the negative battery cable. 2. Remove the generator. 3. Disconnect the throttle position TP sensor electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 6052 4. Remove the TP sensor attaching screws (5). 5. Remove the TP sensor (6). 6. Remove the TP sensor O-ring seal (7). INSTALLATION PROCEDURE 1. Install the TP sensor O-ring seal (7) on the TP sensor (6). 2. Install the TP sensor on the throttle body with the throttle valve in the closed position. Verify the TP sensor lever lines up with the TP sensor drive lever on the throttle shaft. NOTE: Refer to the Fastener Notice in Service Precautions. 3. Install the TP sensor attaching screws (5). Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 6053 4. Connect the TP sensor electrical connector. 5. Install the generator. 6. Connect the negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 4L60-E Park/Neutral Position Switch Screw .................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E > Page 6059 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E Transmission Position Switch/Sensor: Adjustments 4L60-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E > Page 6062 Transmission Position Switch/Sensor: Adjustments 4L80-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E Transmission Position Switch/Sensor: Service and Repair 4L60-E Park Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 6065 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 6066 Transmission Position Switch/Sensor: Service and Repair 4L80-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 6067 4. Position the tool J41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6073 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6074 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6075 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6076 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6077 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6078 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6079 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6080 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6081 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6082 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6083 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6084 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6085 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6086 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6087 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6088 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6089 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6090 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6091 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6092 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6093 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6094 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6095 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6096 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6097 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6098 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6099 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6100 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6101 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6102 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6103 Throttle Position Sensor: Connector Views Throttle Position (TP) Sensor Throttle Position (TP) Sensor (Dual Track) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 6104 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to the Battery Disconnect Caution in Service Precautions. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result. IMPORTANT: If the vehicle is equipped with electronic throttle control (ETC) the throttle position (TP) sensor is NOT serviceable. The throttle body and TP sensor MUST be serviced as a complete assembly. 1. Disconnect the negative battery cable. 2. Remove the generator. 3. Disconnect the throttle position TP sensor electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 6105 4. Remove the TP sensor attaching screws (5). 5. Remove the TP sensor (6). 6. Remove the TP sensor O-ring seal (7). INSTALLATION PROCEDURE 1. Install the TP sensor O-ring seal (7) on the TP sensor (6). 2. Install the TP sensor on the throttle body with the throttle valve in the closed position. Verify the TP sensor lever lines up with the TP sensor drive lever on the throttle shaft. NOTE: Refer to the Fastener Notice in Service Precautions. 3. Install the TP sensor attaching screws (5). Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 6106 4. Connect the TP sensor electrical connector. 5. Install the generator. 6. Connect the negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 4L60-E Park/Neutral Position Switch Screw .................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E > Page 6112 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E Transmission Position Switch/Sensor: Adjustments 4L60-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E > Page 6115 Transmission Position Switch/Sensor: Adjustments 4L80-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E Transmission Position Switch/Sensor: Service and Repair 4L60-E Park Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 6118 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 6119 Transmission Position Switch/Sensor: Service and Repair 4L80-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 6120 4. Position the tool J41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair Catalytic Converter: Service and Repair Catalytic Converter Replacement (4.81- and 5.31- Engines) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the engine shield bolts and shield, if necessary. 3. Remove the oil pan skid plate bolts and plate, if necessary. 4. Unclip the oxygen sensor connection from the floor reinforcement. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Page 6125 5. Remove the clip from around the engine harness and the oxygen sensor pigtail. 6. Disconnect the connector position assurance (CPA) retainers. 7. Disconnect the oxygen sensor electrical connectors. 8. Unclip the oxygen sensors electrical connectors from the following: - Hose clip - Transmission crossmember 9. Disconnect the CPA retainers. 10. Disconnect the oxygen sensor electrical connectors (1, 2). 11. Remove the left exhaust manifold pipe nuts. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Page 6126 12. Remove the right exhaust manifold pipe nuts. 13. Remove the exhaust muffler nuts. 14. Remove the catalytic converter. 15. Remove the oxygen sensors if the catalytic converter is to be replaced. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Page 6127 Notice: Refer to Fastener Notice in Cautions and Notices. 1. If the catalytic converter was replaced, perform the following: 1.1. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors. 1.2. Install the oxygen sensors. - Tighten the oxygen sensors to 42 Nm (31 ft. lbs.). 2. Install the catalytic convertor. 3. Install NEW exhaust manifold pipe seals to the exhaust manifolds. 4. Install the right exhaust manifold pipe nuts until sung. 5. Install the left exhaust manifold pipe nuts until snug. 6. Tighten the right and left exhaust manifold pipe nuts. - Tighten the nuts to 50 Nm (39 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Page 6128 7. Install the exhaust muffler nuts. - Tighten the nuts to 40 Nm (30 ft. lbs.). 8. Connect the oxygen sensor electrical connectors (1, 2). 9. Connect the CPA retainers. 10. Clip the oxygen sensors electrical connectors to the following: - Hose clip - Transmission crossmember 11. Connect the oxygen sensor electrical connectors. 12. Connect the CPA retainers. 13. Install the clip around the engine harness and the oxygen sensor pigtail. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Page 6129 14. Clip the oxygen sensor connection to the floor reinforcement. 15. Install the oil pan skid plate and bolts, if necessary. - Tighten the bolts to 20 Nm (15 ft. lbs.) 16. Install the engine shield and bolts, if necessary. - Tighten the bolts to 20 Nm (15 ft. lbs.). 17. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Description and Operation Canister Purge Control Valve: Description and Operation EVAP PURGE VALVE The EVAP purge valve controls the flow of vapors from the EVAP system to the intake manifold. This normally closed valve is Pulse Width Modulated (PWM) by the control module to precisely control the flow of fuel vapor to the engine. The valve will also be opened during some portions of the EVAP testing, allowing engine vacuum to enter the EVAP system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Description and Operation > Page 6134 Canister Purge Control Valve: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Push the evaporative emission (EVAP) pipe quick connect fitting retainer inward. 3. Disconnect the EVAP pipe (2) from the EVAP purge solenoid (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Description and Operation > Page 6135 4. Disconnect the EVAP purge solenoid electrical connector. 5. Remove the EVAP purge solenoid mount bolt (2). 6. Remove the EVAP purge solenoid (3) and the insulator (1) from the engine. INSTALLATION PROCEDURE 1. Install the insulator (1) on the EVAP canister purge valve (3). 2. Install the EVAP canister purge valve (3) to the engine. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the EVAP canister purge valve mount bolt (2). Tighten Tighten the EVAP canister purge valve mount bolt to 10.5 N.m (93 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Description and Operation > Page 6136 4. Connect the EVAP pipe (2) to the EVAP canister purge valve (1). 5. Connect the EVAP canister purge valve electrical connector. 6. Install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams Evaporative Emission (EVAP) Canister Purge Solenoid Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Page 6140 Canister Purge Solenoid: Description and Operation EVAP Vent Valve The EVAP vent valve controls fresh airflow into the EVAP canister. The valve is normally open. The control module will command the valve closed during some EVAP tests, allowing the system to be tested for leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Vent Valve: > 04-06-04-055A > Mar > 06 > Emissions - SES Lamp ON/DTC P0446 (EVAP) Set Canister Vent Valve: Customer Interest Emissions - SES Lamp ON/DTC P0446 (EVAP) Set Bulletin No.: 04-06-04-055A Date: March 20, 2006 TECHNICAL Subject: LR4, LM4, LM7, L59, LQ9, LQ4, L18 DTC P0446 (Restricted/Blocked EVAP Vent Path) Set, Service Engine Soon (SES) Lamp Illuminated (Replace Vent Solenoid and Bracket) Models: 2000-2003 Cadillac Escalade 2002-2003 Cadillac Escalade EXT 2003 Cadillac Escalade ESV 2000-2003 Chevrolet Suburban, Tahoe 2002-2003 Chevrolet Avalanche 2000-2003 GMC Yukon, Yukon XL with 4.8L, 5.3L, 6.0L, 8.1L Vortec(TM) V8 Engine (VINs V, P, T, Z, N, U, G - RPOs LR4, LM4, LM7, L59, LQ9, LQ4, L18) Supercede: This bulletin is being revised to add updated warranty information and enhance the content. Please discard Corporate Bulletin Number 04-06-04-055 (Section 06 - Engine/Propulsion System). Condition Some customers whose vehicles are operated in dusty type environments, such as farming or mining off-road type applications, may comment about the illumination of the instrument panel SES light, with a DTC of P0446 (Restricted/Blocked EVAP Vent Path) being set. Cause Dirt and dust intrusion into the EVAP canister vent solenoid, resulting in restricted air flow, may cause this condition. Correction After following the Service Manual diagnostic P0446 and determining that the EVAP canister vent valve is the cause of the SES light, replace the existing EVAP canister vent solenoid and bracket. This new vent solenoid has an enhanced filtering capability and a filter element that can be easily removed and cleaned. To ensure correct installation, follow the procedure below. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the bolt retaining the vent valve bracket. 3. Disconnect the electrical connector. 4. Disconnect the canister vent valve hose. 5. Install the new vent valve bracket, P/N 15105605, to the vehicle with the retaining bolt. Tighten Tighten the bracket mounting bolt to 12 N.m (106 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Vent Valve: > 04-06-04-055A > Mar > 06 > Emissions - SES Lamp ON/DTC P0446 (EVAP) Set > Page 6150 6. Install the new vent valve, P/N 10382105, to the bracket. 7. Reinstall the electrical connector. 8. Reinstall the canister vent valve hose. 9. Lower the vehicle. 10. Clear the DTC. Parts Information Warranty Information For vehicles repaired under warranty, use Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Vent Valve: > 04-06-04-055A > Mar > 06 > Emissions - SES Lamp ON/DTC P0446 (EVAP) Set Canister Vent Valve: All Technical Service Bulletins Emissions - SES Lamp ON/DTC P0446 (EVAP) Set Bulletin No.: 04-06-04-055A Date: March 20, 2006 TECHNICAL Subject: LR4, LM4, LM7, L59, LQ9, LQ4, L18 DTC P0446 (Restricted/Blocked EVAP Vent Path) Set, Service Engine Soon (SES) Lamp Illuminated (Replace Vent Solenoid and Bracket) Models: 2000-2003 Cadillac Escalade 2002-2003 Cadillac Escalade EXT 2003 Cadillac Escalade ESV 2000-2003 Chevrolet Suburban, Tahoe 2002-2003 Chevrolet Avalanche 2000-2003 GMC Yukon, Yukon XL with 4.8L, 5.3L, 6.0L, 8.1L Vortec(TM) V8 Engine (VINs V, P, T, Z, N, U, G - RPOs LR4, LM4, LM7, L59, LQ9, LQ4, L18) Supercede: This bulletin is being revised to add updated warranty information and enhance the content. Please discard Corporate Bulletin Number 04-06-04-055 (Section 06 - Engine/Propulsion System). Condition Some customers whose vehicles are operated in dusty type environments, such as farming or mining off-road type applications, may comment about the illumination of the instrument panel SES light, with a DTC of P0446 (Restricted/Blocked EVAP Vent Path) being set. Cause Dirt and dust intrusion into the EVAP canister vent solenoid, resulting in restricted air flow, may cause this condition. Correction After following the Service Manual diagnostic P0446 and determining that the EVAP canister vent valve is the cause of the SES light, replace the existing EVAP canister vent solenoid and bracket. This new vent solenoid has an enhanced filtering capability and a filter element that can be easily removed and cleaned. To ensure correct installation, follow the procedure below. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the bolt retaining the vent valve bracket. 3. Disconnect the electrical connector. 4. Disconnect the canister vent valve hose. 5. Install the new vent valve bracket, P/N 15105605, to the vehicle with the retaining bolt. Tighten Tighten the bracket mounting bolt to 12 N.m (106 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Vent Valve: > 04-06-04-055A > Mar > 06 > Emissions - SES Lamp ON/DTC P0446 (EVAP) Set > Page 6156 6. Install the new vent valve, P/N 10382105, to the bracket. 7. Reinstall the electrical connector. 8. Reinstall the canister vent valve hose. 9. Lower the vehicle. 10. Clear the DTC. Parts Information Warranty Information For vehicles repaired under warranty, use Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Technical Service Bulletins > Page 6157 Evaporative Emission (EVAP) Canister Vent Solenoid Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Technical Service Bulletins > Page 6158 Canister Vent Valve: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the vent pipe (2) from the evaporative emission (EVAP) canister vent valve. 3. Disconnect the EVAP canister vent valve electrical connector (3). 4. Detach the EVAP canister vent valve from the EVAP canister vent valve bracket (1). INSTALLATION PROCEDURE 1. Install the EVAP canister vent valve to the EVAP canister vent valve bracket (1). 2. Connect the EVAP canister vent valve electrical connector (3). 3. Connect the vent pipe (2) to the EVAP canister vent valve. 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair Evaporative Emissions Hose: Service and Repair ENGINE COMPARTMENT EVAP PIPE REMOVAL PROCEDURE IMPORTANT: When replacing the evaporative emission (EVAP) pipe, always replace the pipe with original equipment or pans that meet the GM specifications for this part. The replacement pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection. 1. Clean the pipe connections and the surrounding areas before disconnecting in order to avoid possible contamination of the EVAP system. 2. Disconnect the engine compartment EVAP pipe (2) at the EVAP canister purge solenoid (1). 3. Disconnect the engine compartment EVAP pipe (3) at the chassis EVAP pipe. 4. Remove the EVAP pipe from the engine. 5. Cap the EVAP canister purge solenoid and the chassis EVAP pipe in order to prevent possible EVAP system contamination. ENGINE COMPARTMENT EVAP PIPE INSTALLATION PROCEDURE 1. Remove the caps from the EVAP canister purge solenoid and the chassis EVAP pipe. 2. Install the EVAP pipe on the engine. 3. Connect the engine compartment EVAP pipe (3) to the chassis EVAP pipe. 4. Connect the engine compartment EVAP pipe (2) to the EVAP canister purge solenoid (1). CHASSIS EVAP PIPE REMOVAL PROCEDURE IMPORTANT: When replacing the EVAP pipe, always replace the pipe with original equipment or parts that meet the GM specifications for this part. The replacement pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Page 6162 1. Clean all the EVAP pipe connections and the surrounding areas before disconnecting the pipes in order to avoid possible contamination of the EVAP system. 2. Disconnect the engine compartment EVAP pipe (6) from the chassis EVAP pipe (3). 3. Cap the engine compartment EVAP pipe. 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Remove the EVAP pipe from the bellhousing stud clip (4). 6. Remove the EVAP pipe from the transmission bracket clip. 7. Remove the EVAP pipe from the transfer case bracket clip, 4-wheel drive only. 8. Disconnect the rear EVAP purge pipe from the EVAP canister. 9. Cap the rear EVAP purge pipe (3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Page 6163 10. Note the position of the EVAP pipe for aid in installation. 11. Remove the EVAP pipe from the retaining clips (1). 12. Remove the EVAP pipe. CHASSIS EVAP PIPE INSTALLATION PROCEDURE 1. Install the EVAP pipe into the retaining clips (1). 2. Remove the cap from the rear EVAP pipe. 3. Connect the rear EVAP purge pipe to the EVAP canister. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Page 6164 4. Install the EVAP pipe into the transfer case bracket clip, 4-wheel drive only. 5. Install the EVAP pipe into the transmission bracket clip. 6. Install the EVAP pipe into the bellhousing stud clip (4). 7. Lower the vehicle. 8. Remove the cap from the engine compartment EVAP pipe. 9. Connect the engine compartment EVAP pipe (6) to the chassis EVAP pipe (3). EVAP VENT PIPE REMOVAL PROCEDURE IMPORTANT: When replacing the EVAP pipe, always replace the pipe with original equipment or parts that meet the GM specifications for this part. The replacement pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Page 6165 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Clean all the EVAP pipe connections and the surrounding areas before disconnecting in order to avoid possible contamination of the EVAP system. 3. Disconnect the EVAP vent pipe at the EVAP canister. 4. Disconnect the EVAP vent pipe at the EVAP vent valve. 5. Remove the EVAP vent pipe from the mounting clips (1,3,4, and 5). 6. Cap the EVAP vent valve and the EVAP canister in order to prevent possible EVAP system contamination. EVAP VENT PIPE INSTALLATION PROCEDURE 1. Remove the caps from the EVAP vent valve and the EVAP canister. 2. Connect the EVAP vent pipe (2) to the EVAP vent valve. 3. Connect the EVAP vent pipe to the EVAP canister. 4. Install the EVAP vent pipe into the mounting clips (1,3,4, and 5). 5. Lower the vehicle. REAR EVAP FUEL TANK PIPE REMOVAL PROCEDURE IMPORTANT: When replacing the EVAP pipe, always replace the pipe with original equipment or parts that meet the GM specifications for this part. The replacement pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection. CAUTION: Refer to the Battery Disconnect Caution in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Page 6166 1. Disconnect the negative battery cable. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Utility Single Tank) or Fuel Tank Draining Procedure (Utility Dual Tank Front) or Fuel Tank Draining Procedure (Utility Dual Tank Rear). 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Clean all fuel and EVAP pipe and hose connections and the surrounding areas before disconnection in order to avoid possible contamination of the fuel system. 6. Remove the fuel tank. 7. Remove the rear EVAP pipe (1) from the fuel sender (2), the fuel tank roll over valve (3) and the fuel tank clips (6). 8. Cap the fuel sender EVAP pipe and the fuel tank roll over valve. REAR EVAP FUEL TANK PIPE INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Page 6167 1. Remove the caps from the fuel sender EVAP pipe and the fuel tank roll over valve. 2. Connect the rear EVAP pipe (1) to the fuel sender (2), the fuel tank roll over valve (3), and the fuel tank clips (6). 3. Install the fuel tank. 4. Lower the vehicle. 5. Refill the fuel tank. 6. Connect the negative battery cable. 7. Tighten the fuel filler cap. 8. Inspect for leaks. 8.1. Turn ON the ignition for 2 seconds. 8.2. Turn OFF the ignition for 10 seconds. 8.3. Turn ON the ignition. 8.4. Inspect for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Description and Operation Evaporative System Service Port: Description and Operation EVAP SERVICE PORT The EVAP service port is located in the EVAP purge pipe between the EVAP purge valve and the EVAP canister. The service port is identified by a green colored cap. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair EGR Tube: Service and Repair EXHAUST GAS RECIRCULATION (EGR) PIPE REPLACEMENT REMOVAL PROCEDURE CAUTION: Avoid breathing fumes and swallowing EGR exhaust deposits when removing components for cleaning as bodily injury may result. 1. Remove the engine sight shield. 2. Remove the air intake duct. 3. Remove the exhaust gas recirculation (EGR) valve. 4. Remove the EGR pipe (2) to intake manifold fasteners. 5. Remove the EGR pipe to exhaust manifold fasteners. 6. Remove the EGR pipe mounting fasteners from the right cylinder head. 7. Remove the EGR pipe. INSTALLATION PROCEDURE 1. Install the EGR pipe. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the EGR pipe mounting fasteners to the right cylinder head. Tighten Tighten the fasteners to 50 N.m (37 lb ft). 3. Install the EGR pipe (2) to exhaust manifold fasteners. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Page 6175 Tighten Tighten the fasteners to 25 N.m (18 lb ft). 4. Install the EGR pipe to intake manifold fasteners. Tighten Tighten the fasteners to 12 N.m (106 lb in). 5. Install the EGR valve. 6. Install the air intake duct. 7. Install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications Exhaust Gas Recirculation (EGR) Valve Bolts (First Pass) ................................................................................................................. 10 Nm (89 inch lbs.) EGR Valve Bolts (Final Pass) ...................................................................................................................... ............................................ 30 Nm (22 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 6179 Exhaust Gas Recirculation (EGR) Valve Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 6180 EGR Valve: Service and Repair REMOVAL PROCEDURE IMPORTANT: Do not try to disassemble the exhaust gas recirculation (EGR) valve. Service the valve only as a complete assembly. - Carefully note the position of the EGR valve before removal. Do not rotate the EGR valve 180 degrees. 1. Remove intake duct. 2. Disconnect the EGR electrical connector. 3. Remove the valve to flange attaching fasteners. NOTE: The EGR valve is an electrical component. Soaking the EGR valve in a liquid cleaner or a solvent causes damage to the valve. 4. Remove the EGR valve. 5. Remove the flange gasket. 6. Clean the EGR valve gasket surface. INSTALLATION PROCEDURE 1. Install the new flange gasket 2. Install the EGR valve. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the valve to flange fasteners. Tighten 3.1. Tighten the fasteners the first time to 10 N.m (89 lb in) each. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 6181 3.2. Tighten the fasteners a final time to 25 N.m (18 lb ft) each. 4. Connect the electrical connector. 5. Install intake duct. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair PCV Valve Hose: Service and Repair Crankcase Ventilation Hoses/Pipes Replacement Removal Procedure 1. Remove the engine sight shield. 2. Remove the positive crankcase ventilation (PCV) tube (1) from the intake manifold and valve rocker arm cover. 3. Remove the PCV valve (2) from the PCV tube (1). 4. Remove the vent hose from the throttle body and the valve rocker arm cover. 5. Replace the hose/tube as necessary. Installation Procedure 1. Install the hose/tube as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 6186 2. Install the vent hose to the throttle body and the valve rocker arm cover. 3. Install the PCV valve (2) to the tube (1). 4. Install the PCV tube (1) to the intake manifold and valve rocker arm cover. 5. Install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > Customer Interest for Positive Crankcase Ventilation Valve: > 01-06-01-029B > Jul > 02 > Engine - Greater Than Normal Oil Consumption Positive Crankcase Ventilation Valve: Customer Interest Engine - Greater Than Normal Oil Consumption File In Section: 06 - Engine/Propulsion System Bulletin No.: 01-06-01-029B Date: July, 2002 TECHNICAL Subject: Higher than Expected Engine Oil Consumption (Replace PCV Valve) Models: 2002 Chevrolet Avalanche 1999-2002 Chevrolet Silverado, Suburban, Tahoe Models 2002 Cadillac Escalade, Escalade EXT 1999-2002 GMC Denali, Sierra, Suburban, Yukon Models with 4.8L, 5.3L or 6.0L Engine (VINS V, T, N, U - RPOs LR4, LM7, LQ9, L04) This bulletin is being revised to clarify the parts information. Please discard Corporate Bulletin Number 01-06-01-029A (Section 06 - Engine/Propulsion System). Condition Some customers may comment on higher than expected engine oil consumption. They may further comment on consumption in the range of 3,200 km (2,000 mi) or less per quart (0.946 liter) of oil under normal driving conditions. Cause The condition may be due to the positive crankcase ventilation (PCV) valve flow rate under certain engine operating conditions. Correction 1. Verify that the oil consumption is not the result of an oil leak or other engine concern. 2. The dealer should perform an oil consumption test. The vehicle should have accumulated over 6,450 km (4,000 mi) before establishing the oil consumption rate. Reference Corporate Bulletin Number 01-06-01-011, Information on Engine Oil Consumption Guideline, for details. 3. Remove the PCV valve and inspect the hose going to the intake manifold for signs of excessive oil being present. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > Customer Interest for Positive Crankcase Ventilation Valve: > 01-06-01-029B > Jul > 02 > Engine - Greater Than Normal Oil Consumption > Page 6195 4. If excessive oil is present in the PCV hose, replace the PCV valve (Type 948C) (2) with a new-style fixed orifice PCV valve, GM P/N 12572717 (1). See the illustration shown. Important: The new style fixed orifice PCV valve contains no moving parts, and does not rattle when shaken. If the vehicle has an orifice style PCV valve, investigate other causes for high oil consumption. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Positive Crankcase Ventilation Valve: > 01-06-01-029B > Jul > 02 > Engine - Greater Than Normal Oil Consumption Positive Crankcase Ventilation Valve: All Technical Service Bulletins Engine - Greater Than Normal Oil Consumption File In Section: 06 - Engine/Propulsion System Bulletin No.: 01-06-01-029B Date: July, 2002 TECHNICAL Subject: Higher than Expected Engine Oil Consumption (Replace PCV Valve) Models: 2002 Chevrolet Avalanche 1999-2002 Chevrolet Silverado, Suburban, Tahoe Models 2002 Cadillac Escalade, Escalade EXT 1999-2002 GMC Denali, Sierra, Suburban, Yukon Models with 4.8L, 5.3L or 6.0L Engine (VINS V, T, N, U - RPOs LR4, LM7, LQ9, L04) This bulletin is being revised to clarify the parts information. Please discard Corporate Bulletin Number 01-06-01-029A (Section 06 - Engine/Propulsion System). Condition Some customers may comment on higher than expected engine oil consumption. They may further comment on consumption in the range of 3,200 km (2,000 mi) or less per quart (0.946 liter) of oil under normal driving conditions. Cause The condition may be due to the positive crankcase ventilation (PCV) valve flow rate under certain engine operating conditions. Correction 1. Verify that the oil consumption is not the result of an oil leak or other engine concern. 2. The dealer should perform an oil consumption test. The vehicle should have accumulated over 6,450 km (4,000 mi) before establishing the oil consumption rate. Reference Corporate Bulletin Number 01-06-01-011, Information on Engine Oil Consumption Guideline, for details. 3. Remove the PCV valve and inspect the hose going to the intake manifold for signs of excessive oil being present. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Positive Crankcase Ventilation Valve: > 01-06-01-029B > Jul > 02 > Engine - Greater Than Normal Oil Consumption > Page 6201 4. If excessive oil is present in the PCV hose, replace the PCV valve (Type 948C) (2) with a new-style fixed orifice PCV valve, GM P/N 12572717 (1). See the illustration shown. Important: The new style fixed orifice PCV valve contains no moving parts, and does not rattle when shaken. If the vehicle has an orifice style PCV valve, investigate other causes for high oil consumption. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > Page 6202 Positive Crankcase Ventilation Valve: Service and Repair Positive Crankcase Ventilation (PCV) Valve Replacement Removal Procedure 1. Remove the engine sight shield, if required. 2. Remove the positive crankcase ventilation (PCV) tube (1) from the rocker arm cover. 3. Remove the PCV valve (2) from the PCV tube (1). Installation Procedure 1. Install a new PCV valve (2) to the PCV tube (1). 2. Install the PCV tube (1) to the rocker arm cover. 3. Install the engine sight shield, if required. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Measure with the Key On Engine Off with the fuel pump commanded ON. Vin (V,T,U) Fuel Pressure (gasoline) ..................................................................................................................... ................................................................. 55-62 psi Vin (Z) Fuel Pressure (ethanol) ....................................................................................................................... ................................................................. 48-54 psi These specifications are taken from the Fuel System Diagnosis. For complete testing of fuel pressures and volume see Fuel System Diagnosis, See: Computers and Control Systems/Testing and Inspection Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE CAUTION: ^ Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. ^ Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 1. Install the fuel pressure gauge to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gauge in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gauge. 7. Inspect for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 6209 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST DESCRIPTION Steps 1-2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 6210 Steps 3-7 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 6211 Steps 8-13 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 6212 Steps 14-18 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 6213 Steps 19-25 The numbers below refer to the step numbers on the diagnostic table. 2. This step verifies that the fuel pump is operating. 4. This step tests for an internal fuel leak. If the fuel pressure drops during this test, then an internal loss of pressure is indicated. 6. This step tests the fuel pressure regulator. The fuel pressure regulator is controlled by the engine vacuum. With the engine vacuum applied, the pressure should drop to the specified value. 9. This step inspects the fuel pressure regulator for a fuel leak from the vacuum port. If fuel leaks from the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator. 10. This step tests for a loss of fuel pressure between the fuel feed pipe shut-off adapter and the fuel pump. 11. This step tests for a leaking fuel injector or for a leaking fuel pressure regulator. If the fuel pressure remains constant during this test, the fuel injectors are not leaking fuel. 14. This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, there is a restriction in the fuel return pipe. 16. This step determines if the fuel pressure regulator or the fuel pump is the cause of the low fuel pressure. If the pressure rises above the specified value, the fuel pump is OK. 18. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Thoroughly inspect all fuel electrical circuits. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE CAUTION: ^ Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. ^ Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 1. Install the fuel pressure gauge to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gauge in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gauge. 7. Inspect for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 6218 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance Of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 2. Remove the engine sight shield. 3. Loosen the fuel filler cap in order to relieve the fuel tank vapor pressure. 4. Connect the J 34730-1A to the fuel pressure valve. 5. Install the bleed hose of the gauge into an approved container. 6. Open the valve on the gauge to bleed the system pressure. The fuel connections are now safe for servicing. 7. Drain any fuel remaining in the gauge into an approved container. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed ........................................................................................................................................... .............................................................. 500-700 rpm Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair Accelerator Pedal: Service and Repair ACCELERATOR CONTROLS PEDAL REPLACEMENT REMOVAL PROCEDURE 1. Remove the left instrument panel (IP) insulator. 2. Disconnect the accelerator cable retainer (3) from the accelerator pedal lever (2). 3. Remove the end bushing retaining clips. 4. Remove the end bushings from the pivot shaft. 5. Remove the accelerator pedal. INSTALLATION PROCEDURE 1. Install the accelerator pedal. 2. Install the end bushings to the pivot shaft. 3. Install the end bushing retaining clips. 4. Install the accelerator cable through the slot in the accelerator pedal lever (2). 5. Seat the retainer (3) in the accelerator pedal lever (2). 6. Test for complete throttle opening and closing range by operating the accelerator pedal. Also inspect the carpet fit under the accelerator pedal. The throttle should operate freely and without binding between full closed throttle and wide open throttle (WOT). 7. Install the left IP insulator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6228 Accelerator Pedal Position (APP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6229 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position (APP) Sensor The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 3 individual accelerator pedal position sensors within one housing. Three separate signal, low reference, and 5-volt reference circuits are used to connect the APP and the TAC module. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 1.0 volt at 0 pedal travel to above 2.0 volts at 100 percent pedal travel. APP sensor 2 voltage should decrease from above 4.0 volts at 0 pedal travel to below 2.9 volts at 100 percent pedal travel. APP sensor 3 voltage should decrease from above 3.8 volts at 0 percent pedal travel to below 3.1 volts at 100 percent pedal travel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6230 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the left instrument panel (IP) lower closeout insulator panel. 2. Disconnect the accelerator pedal position (APP) sensor harness connector. Remove the accelerator pedal mounting bolts. 3. Remove the APP assembly. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6231 1. Install the APP assembly to the steering column support bracket. NOTE: Refer to the Fastener Notice in Service Precautions. IMPORTANT: Always use a torque wrench in order to obtain the proper torque. 2. Install the accelerator pedal mounting bolts. Tighten Tighten the accelerator pedal mounting bolts to 20 N.m (15 lb ft). 3. Connect the APP sensor harness connector. 4. Verify that the vehicle meets the following conditions: ^ The vehicle is not in a Reduced Engine Power mode. ^ The ignition is ON. ^ The engine is OFF. 5. Connect a scan tool in order to test for a proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Inspect the carpet fit under the accelerator pedal. 8. Install the left IP lower closeout insulator panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Restriction Indicator > Component Information > Description and Operation Air Cleaner Restriction Indicator: Description and Operation Air Cleaner Restriction Indicator The air cleaner restriction indicator is located on the air cleaner assembly between the air filter and the mass air flow (MAF) sensor. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 6244 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 6250 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 6251 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake duct (2). 2. Disconnect the electrical connector from the mass air flow/intake air temperature (MAF/IAT) sensor. 3. Loosen the 4 fasteners (8) securing the air cleaner housing top cover (4). 4. Lift and rotate the top cover (4) of the air cleaner housing to gain access to the air filter element. 5. Lift out the air filter element (5). 6. Inspect the air filter element for dust, dirt, or water. Clean or replace the air filter element if required. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 6252 1. Install the air filter element (5) into the air cleaner housing. 2. Rotate and install the top cover (4) to the air cleaner housing (6). 3. Insert the fasteners (8) to secure the top cover. 4. Connect the MAF/IAT electrical connector. 5. Install the intake duct. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6258 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6259 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6260 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6261 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6262 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6263 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6264 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6265 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6266 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6267 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6268 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6269 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6270 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6271 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6272 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6273 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6274 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6275 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6276 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6277 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6278 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6279 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6280 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6281 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6282 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6283 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6284 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6285 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6286 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6287 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6288 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 6289 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Take care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. Do not drop or roughly handle the MAF/IAT sensor. 1. Remove air intake resonator. 2. Disconnect the MAF/IAT sensor electrical connector. 3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 6290 2. Install the MAF/IAT sensor on to the air cleaner housing. 3. Tighten the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Connect the MAF/IAT electrical connector. 5. Install air intake resonator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams Fuel Composition Sensor - W/L59 Only Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 6294 Flexible Fuel Sensor: Description and Operation FUEL COMPOSITION SENSOR DESCRIPTION The Fuel Composition Sensor (FCS), or flex fuel sensor (service parts term), measures the ethanol-gasoline ratio of the fuel being used in a flexible fuel vehicle. Flexible fuel vehicles can be operated with a blend of ethanol and gasoline, up to 85 percent ethanol. In order to adjust the ignition timing and the fuel quantity to be injected, the engine management system requires information about the percentage of ethanol in the fuel. The FCS uses quick-connect style fuel connections, an incoming fuel connection, and an outgoing fuel connection. The two connections have different diameters, to prevent incorrect attachment of the fuel lines. All fuel passes through the fuel composition sensor before continuing on to the fuel rail. The fuel composition sensor measures two different fuel related parameters, and sends an electrical signal to the Powertrain Control Module (PCM) to indicate ethanol percentage, and fuel temperature. The fuel composition sensor has a three-wire electrical harness connector. The three wires provide a ground circuit, a power source, and a signal output to the PCM. The power source is vehicle system voltage, +12 volts), and the ground circuit connects to chassis ground. The signal circuit carries both the ethanol percentage and fuel temperature within the same signal, on the same wire. The FCS uses a microprocessor inside the sensor to measure the ethanol percentage and fuel temp, and change an output signal accordingly. The electrical characteristic of the FCS signal is a square-wave digital signal. The signal is both variable frequency and variable pulse width. The frequency of the signal indicates the ethanol percentage, and the pulse width indicates the fuel temperature. The PCM provides an internal pull-up to five volts on the signal circuit, and the FCS pulls the 5 volts to ground in pulses. The output frequency is linear to the percentage of ethanol content in the fuel. The normal range of operating frequency is between 50 and 150 Hertz, with 50 Hertz representing 0 percent ethanol, and 150 Hertz representing 100 percent ethanol. The normal pulse width range of the digital pulses is between 1 and 5 milliseconds, with 1 millisecond representing 40°C (-40°F), and 5 milliseconds representing 125°C (257°F). The microprocessor inside the sensor is capable of a certain amount of self-diagnosis. An output frequency of 170 Hertz indicates either that the fuel is contaminated or contains methanol (it should not), or that an internal sensor electrical fault has been detected. Certain substances dissolved in the fuel can cause the fuel to be contaminated, raising the output frequency to be higher than the actual ethanol percentage should indicate. Examples of these substances include water, sodium chloride (salt), and methanol. It should be noted that it is likely that the FCS will indicate a slightly lower ethanol percentage than what is advertised at the fueling station. This is not a fault of the sensor. The reason has to do with government requirements for alcohol-based motor fuels. Government regulations require that alcohol intended for use as motor fuel be DENATURED. This means that 100 percent pure ethanol is first denatured with approximately 4% percent gasoline, before being mixed with anything else. When an ethanol gasoline mixture is advertised as E85, the 85 percent ethanol was denatured before being blended with gasoline, meaning an advertised E85 fuel contains only about 81 percent ethanol. The FCS measures the actual percentage of ethanol in the fuel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 6295 Flexible Fuel Sensor: Service and Repair FUEL COMPOSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure. 3. Raise the vehicle. 4. Remove the fuel composition sensor fuel composition sensor (FCS) attachment nuts (1). 5. Disconnect the FCS inlet and outlet pipes from the FCS. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 6296 6. Disconnect the FCS electrical connector (1). 7. Remove the FCS and bracket assembly from the frame rail. 8. Remove the FCS bolts and remove from the bracket. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 6297 1. Install the FCS to the bracket and install bolts. Tighten Tighten bolts to 10 N.m (89 lb in). 2. Install FCS and bracket assembly to frame. 3. Install FCS bracket to frame nuts. Tighten Tighten nuts (1) to 17 N.m (13 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 6298 4. Connect the FCS inlet and outlet pipes to the FCS. 5. Connect the FCS electrical connector (1). 6. Lower the vehicle. 7. Start the engine and check for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 6303 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 6304 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 6305 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 6306 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 6307 Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions Bulletin No.: 05-06-04-035C Date: July 30, 2007 INFORMATION Subject: Usage of E85 Fuels in GM Vehicles Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and additional engines with E85 capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System). Customer Interest in E85 Fuel As the retail price of gasoline increases, some locations in the country are seeing price differentials between regular gasoline and E85 where E85 is selling for substantially less than regular grade gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in non-E85 compatible vehicles. Only vehicles designated for use with E85 should use E85 blended fuel. E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15% gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10% ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Using E85 Fuels in Non-Compatible Vehicles General Motors is aware of an increased number of cases where customers have fueled non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in one or more of the following conditions: Lean Driveability concerns such as hesitations, sags and/or possible stalling. SES lights due to OBD codes. Fuel Trim codes P0171 and/or P0174. Misfire codes (P0300). Various 02 sensor codes. Disabled traction control or Stability System disabled messages. Harsh/Firm transmission shifts. Fuel system and/or engine mechanical component degradation. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J 44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with gasoline - preferably one of the Top Tier brands. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 6308 Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at www.livegreengoyellow.com. E85 Compatible Vehicles The only E85 compatible vehicles produced by General Motors are shown. Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or www.livegreengoyellow.com are E85 compatible. All other gasoline and diesel engines are NOT E85 compatible. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 6309 Fuel: Technical Service Bulletins Fuel - Top Tier Detergent Gasoline Information Bulletin No.: 04-06-00-047 Date: June 24, 2004 ADVANCED SERVICE INFORMATION Subject: Top Tier Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) Models: 2005 and Prior All General Motors Passenger Cars and Trucks (U.S. Only) A new class of gasoline, called Top Tier Detergent Gasoline, will be appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by four automotive companies. A description of the concept and benefits of Top Tier is provided in the following question and answer section. What is Top Tier Detergent Gasoline? Top Tier Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by four automotive companies that exceed the detergent requirements imposed by the EPA. Who developed Top Tier Detergent Gasoline standards? Top Tier Detergent Gasoline standards were developed by four automotive companies: BMW, General Motors, Honda and Toyota. Why was Top Tier Detergent Gasoline developed? Top Tier Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet Top Tier Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, Top Tier was developed to give fuel marketers the opportunity to differentiate their product. Why did the four automotive companies join together to develop Top Tier? All four corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of Top Tier Detergent Gasoline? Top Tier Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of Top Tier Detergent Gasoline will help reduce deposit related concerns. Who should use Top Tier Detergent Gasoline? All vehicles will benefit from using Top Tier Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from use of Top Tier Detergent Gasoline. Where can Top Tier Detergent Gasoline be purchased? The Top Tier program began on May 3, 2004. Some fuel marketers have already joined and are making plans to introduce Top Tier Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, a list of all fuel marketers meeting Top Tier standards will be made available. For now, look for the "Top Tier" designation at the gas pump. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 6310 Fuel: Description and Operation FUEL SYSTEM SPECIFICATIONS Use regular unleaded gasoline rated at 87 octane or higher. The manufacturer recommends that the gasoline meet the specifications which have been developed by the American Automobile Manufacturers Association (AAMA) and endorsed by the Canadian Motor Vehicle Manufacturers Association for better vehicle performance and engine protection. Gasoline meeting the AAMA specification may provide improved driveability and emission control system performance compared to other gasoline. For more information, write to: American Automobile Manufacturer's Association, 7430 Second Ave., Suite 300, Detroit, MI, 48202. Verify that the posted octane is at least 87. If the octane is less than 87, you may get a heavy knocking noise when you drive. If the engine knock is bad enough, your engine may be damaged. If you are using fuel rated at 87 octane or higher and you hear heavy knocking, your engine needs service. Do not worry if you hear a little pinging noise when you are accelerating or driving up a hill. This is normal and you do not have to buy a higher octane fuel to get rid of pinging. Only the heavy, constant knock means that you have a problem. NOTE: Your vehicle was not designed for fuel that contains methanol. Do not use methanol fuel which car corrode metal parts in your fuel system and also damage plastic and rubber parts. This kind of damage would not be covered under your warranty. If your vehicle is certified to meet California emission standards, indicated on the underhood emission control label, your vehicle is designed to operate on fuels that meet California specifications. If such fuels are not available in states adopting California emission standards, your vehicle operates satisfactorily on fuels meeting federal specifications, but emission control system performance may be affected. The Malfunction Indicator Lamp (MIL) on your instrument panel may turn ON, and your vehicle may fail a smog-check test. If this occurs, return to your authorized dealer for diagnosis in order to determine the cause of failure. In the event that the cause of the condition is determined to be the type of fuels used, repairs may not be covered by your warranty. Some gasolines that are not reformulated for low emissions may contain an octane-enhancing additive called Methylcyclopentadienyl Manganese Tricarbonyl (MMT). Ask your service station operator whether or not the fuel contains MMT. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Alcohol/Contaminants-In-Fuel Diagnosis (W/ Special Tool) Fuel: Testing and Inspection Alcohol/Contaminants-In-Fuel Diagnosis (W/ Special Tool) TEST DESCRIPTION Fuel quality can effect vehicle performance. Gasoline and gasoline blends that are contaminated or contain excessive amounts of alcohol can effect vehicle driveability, fuel economy, fuel system components and emissions. Excessive alcohol in the fuel may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Some types of alcohol are more detrimental to fuel system components than others. Ethanol is commonly used in gasoline, but in concentrations of no more than 10 percent. Some fuels, such as E85, contain a very high percent of ethanol. Fuel with more than 15 percent ethanol may cause driveability conditions in vehicles such as hesitation, lack of power, stalling, or no start. If excessive alcohol in the fuel is suspected, then use the following procedure to test the fuel quality. TEST PROCEDURE CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. 1. Turn ON the J 44175 Fuel Composition Tester. 2. Verify the fuel composition tester is operational by measuring the IAC frequency output with a DMM. Refer to Measuring Frequency in Diagnostic Aids. A frequency without a fuel sample in the test cell indicates that the tester is working correctly. 3. Install the fuel pressure gage. Refer to Fuel Pressure Gage Installation and Removal. IMPORTANT: You will need to bleed the fuel pressure gage a few times in order to obtain an accurate fuel sample. 4. Close the bleed valve on the fuel pressure gage. 5. Place the bleed hose (1) of the fuel pressure gage into the 100 ml beaker. 6. Command the fuel pump ON with a scan tool. 7. Slowly open the bleed valve on the fuel pressure gage, until an adequate fuel sample is obtained. 8. If water appears in the fuel sample, clean the fuel system and replace the fuel in the vehicle. Refer to Fuel System Cleaning. IMPORTANT: Do not allow any substances other than gasoline, ethanol/gasoline blends, air, or acetone into the test ports of the fuel composition tester. Contaminants in the fuel composition tester could result in misdiagnosis. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Alcohol/Contaminants-In-Fuel Diagnosis (W/ Special Tool) > Page 6313 9. Pour the fuel sample from the beaker (1) into the J 44175, until the level of the fuel is at the top of each fuel test port (2). 10. Observe the diagnostic LEDs on the fuel composition tester. If the red fuel diagnostic LED is illuminated, a fuel contamination condition exists. Refer to Fuel System Cleaning. 11. Measure the output frequency of the fuel composition tester. Fuel Composition Test Examples 12. Subtract 50 from the reading on the DMM to obtain the percentage of alcohol in the fuel sample. Refer to the examples in the table. 13. If the fuel sample contains more than 15 percent ethanol, replace the fuel in the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Alcohol/Contaminants-In-Fuel Diagnosis (W/ Special Tool) > Page 6314 Fuel: Testing and Inspection Alcohol/Contaminants-In-Fuel Diagnosis (W/O Special Tool) Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel rail, and cause a misfire in that cylinder If the fuel system is contaminated with water, inspect the fuel system components for rust, or deterioration. Alcohol concentrations of 10 percent or greater in fuel can be detrimental to fuel system components. Alcohol contamination may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Fuel contaminated with alcohol may cause driveability conditions such as hesitation, lack of power, stalling, or no start. Some types of alcohol are more detrimental to fuel system components than others. Alcohol in Fuel Testing Procedure The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If alcohol contamination is suspected then use the following procedure to test the fuel quality. 1. Using a 100 ml specified cylinder with 1 ml graduation marks, fill the cylinder with fuel to the 90 ml mark. 2. Add 10 ml of water in order to bring the total fluid volume to 100 ml and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml. For example, if the volume of the lower layer is increased to 15 ml, this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. Particulate Contaminants in Fuel Testing Procedure The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the bottom of the sample, use the following procedure to diagnose the fuel. 1. Using an approved fuel container, draw approximately 0.5 liter of fuel. 2. Place the cylinder on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by a white or light brown crystals. Rubber will appear as black and irregular particles. If particles are found clean the entire fuel system thoroughly. Refer to Fuel System Cleaning. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Alcohol/Contaminants-In-Fuel Diagnosis (W/ Special Tool) > Page 6315 Steps 1-7 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Page 6316 Fuel: Service and Repair FUEL SYSTEM CLEANING 1. Remove the fuel sender assembly. 2. Inspect the fuel strainer. Replace a contaminated strainer and inspect the fuel pump. 3. Inspect the fuel pump inlet for dirt and debris. Replace the fuel pump if you find dirt or debris in the fuel pump inlet. IMPORTANT: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water mixture in accordance with all applicable local, state, and federal laws and regulations. 4. Flush the fuel tank with hot water. 5. Pour the water out of the fuel sender assembly opening. Rock the tank to be sure that removal of the water from the tank is complete. 6. Install the fuel sender assembly Replacement. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation Fuel Filler Cap The fuel fill pipe has a tethered fuel filler cap. A torque-limiting device prevents the cap from being over tightened. To install the cap, turn the cap clockwise until you hear clicks. This indicates that the cap is correctly torqued and fully seated. A built-in device indicates that the fuel filler cap is fully seated. A fuel filler cap that is not fully seated may cause a malfunction in the emission system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE CAUTION: ^ Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. ^ Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 1. Install the fuel pressure gauge to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gauge in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gauge. 7. Inspect for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 6325 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance Of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 2. Remove the engine sight shield. 3. Loosen the fuel filler cap in order to relieve the fuel tank vapor pressure. 4. Connect the J 34730-1A to the fuel pressure valve. 5. Install the bleed hose of the gauge into an approved container. 6. Open the valve on the gauge to bleed the system pressure. The fuel connections are now safe for servicing. 7. Drain any fuel remaining in the gauge into an approved container. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Injector Ohms ...................................................................................................................................... ............................................................... 11-14 ohms Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 6332 Fuel Injector: Pressure, Vacuum and Temperature Specifications Pressure Drop (of average psi) ........................................................................................................... ......................................................................... 1.5 psi Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6335 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6336 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6337 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6338 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6339 Fuel Injector: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6340 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6341 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6342 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6343 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6344 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6345 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6346 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6347 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6348 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6349 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6350 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6351 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6352 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6353 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6354 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6355 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6356 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6357 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6358 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6359 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6360 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6361 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6362 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6363 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6364 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6365 Fuel Injector: Connector Views Fuel Injector 1 Fuel Injector 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6366 Fuel Injector 3 Fuel Injector 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6367 Fuel Injector 6 Fuel Injector 5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 6368 Fuel Injector 7 Fuel Injector 8 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test Fuel Injector: Testing and Inspection Fuel Injector Coil Test CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector on the intake stroke for each cylinder. Ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. DIAGNOSTIC AIDS ^ Monitoring the misfire current counters, or misfire graph, may help isolate the fuel injector that is causing the condition. ^ Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. ^ Perform the fuel injector coil test within the conditions of the customers concern. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. ^ If the fuel injector coil test does not isolate the condition perform the fuel injector balance test. Refer to Fuel Injector Balance Test with Special Tool or Fuel Injector Balance Test with Tech 2. TEST DESCRIPTION Steps 1-7 The numbers below refer to the step numbers on the diagnostic table. 3. This step tests each fuel injector resistance within a specific temperature range. If any of the fuel injectors display a resistance outside of the specified value, replace the fuel injector. 4. This step determines if all of the fuel injectors are within 3 ohms of each other. If the highest resistance value is within 3 ohms of the lowest resistance value, then all of the fuel injector coil windings are OK. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 6371 5. This step determines which fuel injector is faulty. After subtracting the highest and lowest resistance values from the average value, replace the fuel injector that has the greatest resistance difference from the average. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 6372 Fuel Injector: Testing and Inspection Fuel Injector Balance Test With special Tool CIRCUIT Fuel Injector Balance Test With Special Tool Fuel Injector Balance Test Example (Typical) TEST DESCRIPTION Steps 1-3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 6373 Steps 4-8 The numbers below refer to the step numbers on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. 6. If the pressure drop value for each fuel injector is within 10 kPa (1.5 psi) of the average pressure drop value, the fuel injectors are flowing properly. Calculate the pressure drop value for each fuel injector by subtracting the second pressure reading from the first pressure reading. Refer to the illustration. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 6374 Fuel Injector: Testing and Inspection Fuel Injector Balance Test with Tech 2 CIRCUIT DESCRIPTION The scan tool first energizes the fuel pump and then the injectors for a precise amount of time allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Steps 1-4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 6375 Steps 5-8 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 6376 Steps 1-7 The numbers below refer to the step numbers on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. 4. The fuel pressure should be within the specified range. Refer to Fuel System Diagnosis if the fuel pressure is not within the specified range. 5. The fuel pressure should reach a steady value. Refer to Fuel System Diagnosis if the fuel pressure does not stabilize. 6. If the pressure drop value for each fuel injector is within 10 kPa (1.5 psi) of the average pressure drop value, the fuel injectors are flowing properly. Calculate the pressure drop value for each fuel injector by subtracting the second pressure reading from the first pressure reading. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 6377 Fuel Injector: Service and Repair REMOVAL PROCEDURE NOTE: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method. IMPORTANT: ^ The Denso fuel injectors that are installed on the 5.3L (L59) E85 application will not have O-rings and retaining clips serviced separately. Therefore the fuel injectors will be replaced whenever an O-ring or clip needs to be replaced. ^ The engine oil may be contaminated with fuel if the fuel injectors are leaking. 1. Remove the fuel rail. 2. Remove the fuel injector retainer clip (19). 3. Remove the fuel injector (17). 4. Discard the fuel injector retainer clip (1). 5. Remove and discard the fuel injector O-ring seals (2, 4) from the injector. INSTALLATION PROCEDURE IMPORTANT: When ordering new fuel injectors, you must order the correct injector for the application being serviced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 6378 1. The fuel injector (1) is stamped with a part number identification (2). A four-digit build date code (3), which indicates the month (4), day (5), year (6), and the shift (7) that built the fuel injector. 2. Lubricate the NEW fuel injector O-ring seals (2, 4) with clean engine oil. 3. Install the NEW fuel injector O-ring seals onto the fuel injector. 4. Install a NEW retainer clip (1) onto the fuel injector. 5. Install the fuel injector (17) into the fuel rail injector socket with the electrical connector facing outward. The retainer clip (19) locks on to a flange on the fuel rail injector socket. 6. Install the fuel rail. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation QUICK-CONNECT FITTINGS Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs inside the female connector hold the fittings together. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Metal Collar) TOOL REQUIRED J 37088-A Tool Set, Fuel Line Quick-Connect Separator REMOVAL PROCEDURE 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel Pressure Relief Procedure. 2. Remove the retainer from the quick-connect fitting. CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury. 3. Blow dirt out of the fitting using compressed air. 4. Choose the correct tool from the J 37088-A tool set for the size of the fitting. Insert the tool into the female connector, then push inward in order to release the locking tabs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 6384 5. Pull the connection apart. NOTE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 6. Use a clean shop towel in order to wipe off the male pipe end. 7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. INSTALLATION PROCEDURE CAUTION: Always apply a few drops Of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male pipe end. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 6385 2. Push both sides of the fitting together in order to snap the retaining tabs into place. 3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure. 4. Install the retainer to the quick-connect fitting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 6386 Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Plastic Collar) REMOVAL PROCEDURE 1. Relieve the fuel system pressure before servicing any fuel system Connection. Refer to Fuel Pressure Relief Procedure. CAUTION: Refer to Safety Glasses and Compressed Air Caution in Service Precautions. 2. Using compressed air, blow any dirt out of the quick-connect fitting. 3. Squeeze the plastic retainer release tabs. 4. Pull the connection apart. INSTALLATION PROCEDURE CAUTION: Refer to Fuel Pipe Fitting Caution in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 6387 1. Apply a few drops of clean engine oil to the male fuel pipe end. 2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place. 3. Once installed, pull on both sides of the quick-connect fitting in order to make sure the connection is secure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator Assembly The fuel pressure regulator is a vacuum-operated diaphragm relief valve with fuel pump pressure on one side, and with regulator spring pressure and intake manifold vacuum on the other side. The fuel pressure regulator maintains a constant pressure differential across the injectors at all times. The pressure regulator compensates for engine load by increasing the fuel pressure when the engine vacuum drops. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 6391 Fuel Pressure Regulator: Service and Repair REMOVAL PROCEDURE IMPORTANT: Three styles of fuel pressure regulators and fuel rails will be used in this model year. Each regulator has a different "footprint" that consequently changes the size of the receiving port in the fuel rail. The regulator retaining clips are specific to each rail-regulator design and cannot be interchanged. 1. Remove the engine sight shield. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Disconnect the fuel pressure regulator vacuum line. 4. Clean any dirt from the fuel pressure regulator retainer and the surrounding area. 5. Remove the fuel pressure regulator retainer (8). 6. Remove the fuel pressure regulator (9). 7. Ensure none of the following parts are still in the fuel rail: ^ Backup ring (10) ^ Regulator Seal O-ring (11) ^ Regulator filter (12) ^ Regulator seal O-ring (13) INSTALLATION PROCEDURE 1. Ensure that the NEW fuel pressure regulator retainer is the correct one. 2. The tabs (1) are used on the straight vacuum port retainer (2), and the E85-straight vacuum port retainer (3). 3. The angle vacuum port retainer (4) has no tabs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 6392 4. Install the following parts onto the fuel pressure regulator (9), if necessary. ^ Backup ring (10) ^ Regulator seal O-ring (11) ^ Regulator filter (12) ^ Regulator seal O-ring (13) 5. Lubricate the fuel pressure regulator O-rings (11,13) with clean engine oil. 6. Install the fuel pressure regulator (9). IMPORTANT: Whenever the fuel pressure regulator is removed from the fuel rail NEW O-rings and a NEW retaining clip should be used on reinstallation. 7. Install the NEW fuel pressure regulator retainer (8). 8. Connect the fuel pressure regulator vacuum line. 9. Tighten the fuel filler cap. 10. Inspect for leaks. 10.1. Turn ON the ignition with the engine OFF, for 2 seconds. 10.2. Turn OFF the ignition for 10 seconds. 10.3. Turn ON the ignition, with the engine OFF. 10.4. Inspect for fuel leaks. 11. Install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Measure with the Key On Engine Off with the fuel pump commanded ON. Vin (V,T,U) Fuel Pressure (gasoline) ..................................................................................................................... ................................................................. 55-62 psi Vin (Z) Fuel Pressure (ethanol) ....................................................................................................................... ................................................................. 48-54 psi These specifications are taken from the Fuel System Diagnosis. For complete testing of fuel pressures and volume see Fuel System Diagnosis, See: Computers and Control Systems/Testing and Inspection Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE CAUTION: ^ Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. ^ Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 1. Install the fuel pressure gauge to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gauge in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gauge. 7. Inspect for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 6399 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST DESCRIPTION Steps 1-2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 6400 Steps 3-7 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 6401 Steps 8-13 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 6402 Steps 14-18 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 6403 Steps 19-25 The numbers below refer to the step numbers on the diagnostic table. 2. This step verifies that the fuel pump is operating. 4. This step tests for an internal fuel leak. If the fuel pressure drops during this test, then an internal loss of pressure is indicated. 6. This step tests the fuel pressure regulator. The fuel pressure regulator is controlled by the engine vacuum. With the engine vacuum applied, the pressure should drop to the specified value. 9. This step inspects the fuel pressure regulator for a fuel leak from the vacuum port. If fuel leaks from the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator. 10. This step tests for a loss of fuel pressure between the fuel feed pipe shut-off adapter and the fuel pump. 11. This step tests for a leaking fuel injector or for a leaking fuel pressure regulator. If the fuel pressure remains constant during this test, the fuel injectors are not leaking fuel. 14. This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, there is a restriction in the fuel return pipe. 16. This step determines if the fuel pressure regulator or the fuel pump is the cause of the low fuel pressure. If the pressure rises above the specified value, the fuel pump is OK. 18. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Thoroughly inspect all fuel electrical circuits. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay Fuel Pump Relay: Locations Fuel Pump Relay FUEL PUMP RELAY Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 6408 Locations View The Fuel Pump (FP) Relay is located in the Underhood Fuse Block. The Underhood Fuse Block is located at the left side of the engine compartment near the battery. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 6409 Fuel Pump Relay: Locations Fuel Pump Relay Secondary - With Dual Tanks SECONDARY FUEL PUMP RELAY (With Dual Tanks Only) Locations View The Secondary Fuel Pump (FP) Relay (1) is attached to the Underhood Fuse Block on bracket. The Underhood Fuse Block is located at the left side of the engine compartment near the battery. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 6410 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6413 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6414 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6415 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6416 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6417 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6418 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6419 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6420 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6421 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6422 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6423 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6424 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6425 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6426 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6427 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6428 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6429 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6430 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6431 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6432 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6433 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6434 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6435 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6436 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6437 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6438 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6439 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6440 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6441 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6442 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6443 Fuel Pump (FP) Relay-Secondary Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation Fuel Rail: Description and Operation Fuel Rail Assembly The fuel rail assembly attaches to the engine intake manifold. The fuel rail assembly performs the following functions: ^ Positions the injectors (3) in the intake manifold ^ Distributes fuel evenly to the injectors ^ Integrates the fuel pressure regulator (2) with the fuel metering system Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement Fuel Rail: Service and Repair Fuel Rail Assembly Replacement REMOVAL PROCEDURE IMPORTANT: An eight-digit identification number (1) is located on the fuel rail. Refer to this model identification number if service or part replacement is required. 1. Remove the engine sight shield. 2. Before removal, if necessary, clean the fuel rail assembly with a spray type engine cleaner, use GM X-30A or equivalent. Follow the package instructions. Do not soak fuel rail assembly in any liquid cleaning solvents. 3. Disconnect the accelerator control and cruise control cables from the cable bracket, if equipped. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement > Page 6452 4. Disconnect the cruise control cable engine-end fitting from the stud on the throttle lever, if equipped. 5. Disconnect the accelerator control cable from the throttle lever, if equipped. 6. Remove the upper engine wire harness retainer nut. 7. Disconnect the evaporative emission (EVAP) purge solenoid electrical connector. 8. Reposition the upper engine wire harness aside. 9. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement > Page 6453 10. Mark the electrical connectors to their corresponding injectors to ensure correct sequential injector firing order after reassembly. IMPORTANT: When disconnecting the Multec (R) 2 fuel injector connectors, DO NOT use pliers or other hand tools, as the connector ends may become mangled and be rendered unusable. 11. Pull the connector position assurance (CPA) (2) on the injector connector up. 12. Push the tab (1) on the injector connector in. 13. While pushing the tab (1) on the injector connector in, release the CPA (2). 14. Disconnect the fuel injector connector electrical connector. 15. Repeat the steps for each injector connector. NOTE: ^ Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components. ^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement > Page 6454 16. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail. 17. Disconnect the fuel pressure regulator vacuum line. 18. Loosen the retaining clip attaching screw (22) at the right hand fuel rail. 19. Remove the fuel rail bolts. 20. Remove the fuel rail. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement > Page 6455 21. Remove and discard the fuel injector lower O-ring seals (4) from the injectors (3). INSTALLATION PROCEDURE 1. Lubricate the NEW fuel injector lower O-ring seals (4) with clean engine oil. 2. Install the NEW O-ring seals (4) to the end of each fuel injector (3). 3. Remove the retaining clip attaching screw (22) and crossover pipe retainer (21) to the right hand fuel rail. 4. Remove the crossover pipe rail (25) from the right fuel rail (15). 5. Remove the crossover pipe O-ring (20). 6. Lubricate a NEW O-ring (20) with clean engine oil. 7. Install a NEW crossover pipe O-ring (20) on the crossover pipe (25). 8. Install the crossover pipe (25) into the right fuel rail (15). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement > Page 6456 IMPORTANT: When installing the retaining clip attaching screw for the crossover pipe, always start the screw by hand. This will prevent consequent stripping of the threads in the fuel rail. 9. Loosely install the crossover pipe retainer (21) and retaining clip attaching screw (22) to the right hand fuel rail. 10. Install the fuel rail. 11. Apply a 5 mm (0.020 in) band of GM P/N 12345382 threadlock, or equivalent, to the threads of the fuel rail bolts. NOTE: Refer to the Fastener Notice Cautions and Notices. 12. Install the fuel rail bolts. Tighten 12.1. Tighten the bolts to 10 N.m (89 lb in). 12.2. Tighten the screw to 3.8 N.m (34 lb in). 13. Connect the fuel pressure regulator vacuum line. 14. Connect the fuel feed and return pipes (1, 2) to the fuel rail. 15. Connect the fuel injector electrical connectors. ^ Install each electrical connector onto the correct fuel injector in order to ensure correct sequential injector firing order. ^ Rotate the fuel injectors as required in order to avoid stretching the wire harness. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement > Page 6457 16. Position the upper engine wire harness in place. 17. Connect the EVAP purge solenoid electrical connector. 18. Install the retainer nut to the upper engine wire harness. Tighten Tighten the nut to 5.5 N.m (49 lb in). 19. Connect the accelerator control and cruise control cables to the cable bracket, if equipped. 20. Connect the accelerator control cable to the throttle body, if equipped. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement > Page 6458 21. Connect the cruise control cable engine-end fitting to the stud on the throttle lever, if equipped. 22. Use the following procedure in order to inspect for leaks: 22.1. Turn ON the ignition, with the engine OFF, for 2 seconds. 22.2. Turn OFF the ignition for 10 seconds. 22.3. Turn ON the ignition, with the engine OFF. 22.4. Inspect for fuel leaks. 23. Install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement > Page 6459 Fuel Rail: Service and Repair Fuel Rail Crossover Pipe Replacement REMOVAL PROCEDURE IMPORTANT: The fuel rail for the 5.3L regular production option (RPO) L59 (VIN Z) is compatible with fuel that has a composition of up to 85 percent Ethanol (E85). Because of this the fuel rail will be serviced as an entire assembly that includes both left and right rail assemblies and the crossover pipe rail. 1. Remove the engine sight shield. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Disconnect the fuel feed (1) and fuel return (2) pipes from the fuel rail. 4. Remove the fuel return pipe attaching screw (3) and the fuel return pipe retainer (2). 5. Remove the fuel return pipe (1). 6. Remove and discard the fuel return pipe O-ring (6). 7. Remove the fuel pressure connection core assembly (24) from the crossover pipe rail (25). 8. Remove the retaining clip attaching screw (22) and the crossover fuel pipe retainer clip (21). 9. Remove the retaining clip attaching screw (4) and the crossover fuel pipe retainer clip (5). 10. Remove the crossover pipe rail assembly (25) from the left hand rail assembly (14) and the right hand rail assembly (15). 11. Remove and discard the crossover fuel pipe O-rings (7, 20). INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement > Page 6460 1. Lubricate the NEW crossover fuel pipe O-rings (7, 20) with clean engine oil. 2. Install the NEW crossover fuel pipe O-rings (7, 20) onto the crossover pipe rail assembly (25). 3. Install the crossover pipe rail assembly (25) to the left hand rail assembly (14) and the right hand rail assembly (15). NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads in the rail. 4. Install the crossover fuel pipe retainer clip (21). Loosely install the retaining clip attaching screw (22). 5. Lubricate the NEW fuel return pipe O-ring (6) with clean engine oil. 6. Install the NEW fuel return pipe O-ring (6) on the fuel return pipe (1). 7. Install the fuel return pipe (1). 8. Install the fuel return pipe retainer (2). Loosely install the fuel return pipe attaching screw (3). IMPORTANT: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads in the rail. 9. Install the crossover fuel pipe retainer clip (5). Loosely install the retaining clip attaching screw (4). Tighten 9.1. Tighten the crossover fuel pipe retainer clip attaching screws (4, 22) to 3.8 N.m (34 lb in). 9.2. Tighten the fuel return pipe attaching screw (3) to 5 N.m (44 lb in). 10. Install the fuel pressure connection core assembly (24) to the crossover pipe rail assembly (25). 11. Connect the fuel return (2) and fuel feed (1) pipes to the fuel rail. 12. Tighten the fuel fill cap. 13. Connect the negative battery cable. 14. Use the following procedure in order to inspect for leaks: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement > Page 6461 14.1. Turn ON the ignition, with the engine OFF, for 2 seconds. 14.2. Turn OFF the ignition for 10 seconds. 14.3. Turn ON the ignition, with the engine OFF. 14.4. Inspect for fuel leaks. 15. Install the fuel pressure connection cap. 16. Install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement > Page 6462 Fuel Rail: Service and Repair Fuel Rail Outlet Pipe Replacement REMOVAL PROCEDURE IMPORTANT: The fuel rail for the 5.3L regular production option (RPO) L59 (VIN Z) is compatible with fuel that has a composition of up to 85 percent Ethanol (E85). Because of this the fuel rail will be serviced as an entire assembly that includes both left and right rail assemblies and the fuel return pipe. 1. Remove the engine sight shield. 2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure. 3. Disconnect the fuel feed (1) and fuel return (2) pipes from the fuel rail. 4. Remove the retaining clip attaching screw (4). 5. Remove the crossover fuel pipe retainer clip (5). 6. Remove the fuel return pipe attaching screw (3) and the fuel return pipe retainer (2). 7. Remove the fuel return pipe (1). 8. Remove and discard the fuel return pipe O-ring (6). INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement > Page 6463 1. Lubricate a NEW fuel return pipe O-ring (6) with clean engine oil. 2. Install the fuel return pipe O-ring (6) onto the fuel return pipe (1). 3. Install the fuel return pipe (1). NOTE: Refer to the Fastener Notice in Service Precautions. 4. Install the fuel return pipe retainer (2) and the fuel return pipe attaching screw (3). 5. Install the crossover fuel pipe retainer clip (5). IMPORTANT: When installing the retaining clip attaching screw for the crossover pipe, always start the screw by hand. This will prevent consequent stripping of the threads in the rail. 6. Install the retaining clip attaching screw (4). Tighten 6.1. Tighten the crossover fuel pipe retainer clip attaching screw (4) to 3.8 N.m (34 lb in). 6.2. Tighten the fuel return pipe attaching screw (3) to 5 N.m (44 lb in). 7. Connect the fuel return (2) and the fuel feed (1) pipes to the fuel rail. 8. Tighten the fuel filler cap. 9. Connect the negative battery cable. 10. Use the following procedure in order to inspect for leaks: 10.1. Turn ON the ignition, with the engine OFF, for 2 seconds. 10.2. Turn OFF the ignition for 10 seconds. 10.3. Turn ON the ignition, with the engine OFF. 10.4. Inspect for fuel leaks. 11. Install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel Feed and Return Pipes Fuel Supply Line: Description and Operation Fuel Feed and Return Pipes The fuel feed pipe carries fuel from the fuel tank to the fuel rail assembly. The fuel return pipe carries fuel from the fuel rail assembly back to the fuel tank. The fuel pipes consist of 2 sections: ^ The rear fuel pipe assemblies are located from the top of the fuel tank to the chassis fuel pipes. The rear fuel pipes are constructed of nylon. ^ The chassis fuel pipes are located under the vehicle and connect the rear fuel pipes to the fuel rail pipes. These pipes are constructed of steel with sections of rubber hose covered with braiding. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel Feed and Return Pipes > Page 6468 Fuel Supply Line: Description and Operation Nylon Fuel Pipes CAUTION: Refer to Fuel and EVAP Pipe Caution in Service Precautions. Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There are 3 sizes of nylon pipes used: 9.5 mm (3/8 in.) ID for the fuel feed, 7.6 mm (5/16 in.) ID for the fuel return, and 12.7 mm (1/2 in.) ID for the vent. Heat resistant rubber hose or corrugated plastic conduit protect the sections of the pipes that are exposed to chafing, to high temperatures, or to vibration. Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle. However, if nylon fuel pipes are forced into sharp bends, the pipes kink and restrict the fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Take special care when working on a vehicle with nylon fuel pipes. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel Feed and Return Pipes > Page 6469 Fuel Supply Line: Description and Operation Fuel Pipe O-Rings O-rings seal the threaded connections in the fuel system. Fuel system O-ring seals are made of special material. Service the O-ring seals with the correct service part. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure. 2. Clean all the fuel pipe connections and the surrounding areas before disconnecting the pipes in order to avoid possible contamination of the fuel system. 3. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail. 4. Cap the fuel rail pipes. 5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 6. Remove the fuel pipes from the bellhousing stud clip (4). 7. Remove the fuel pipes from the transmission bracket clip. 8. Remove the fuel pipes from the transfer case bracket clip, 4-wheel drive only. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 6472 9. Remove the evaporative emission (EVAP) canister from the vehicle. 10. Disconnect the chassis fuel feed and return pipes at the rear fuel feed and return pipes. 11. Cap the rear fuel pipes. 12. Note the position of the fuel pipes for aid in installation. 13. Remove the fuel pipes from the retaining clips (1). 14. Remove the fuel pipes. INSTALLATION PROCEDURE IMPORTANT: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 6473 ^ When replacing the fuel pipes, always replace them with original equipment or parts that meet the GM specifications for those parts. The replacement pipes must have the same type of fittings as the original pipes in order to ensure the integrity of the connection. ^ DO NOT use copper or aluminum tubing to replace steel tubing. Only tubing meeting the 124-M specification or the equivalent is capable of meeting all pressure, corrosion and vibration characteristics necessary to ensure the durability standard required. 1. Install the fuel pipes into the retaining clips (1). 2. Remove the caps from the rear fuel pipes. 3. Connect the chassis fuel feed and return pipes at the rear fuel feed and return pipes. 4. Install the EVAP canister. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 6474 5. Install the fuel pipes into the transfer case bracket clip, 4 wheel drive only. 6. Install the fuel pipes into the transmission bracket clip. 7. Install the fuel pipes into the bellhousing stud clip (4). 8. Lower the vehicle. 9. Remove the caps from the fuel rail pipes. 10. Connect the fuel feed and return pipes (1, 2) to the fuel rail. 11. Tighten the fuel filler cap. 12. Connect the negative battery cable. 13. Use the following procedure in order to inspect for leaks: 13.1. Turn ON the ignition, with the engine OFF, for 2 seconds. 13.2. Turn OFF the ignition for 10 seconds. 13.3. Turn ON the ignition, with the engine OFF. 13.4. Inspect for fuel leaks. 14. Install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 6475 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Assembly Replacement REMOVAL PROCEDURE 1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in order to avoid possible contamination of the fuel system. 2. Remove the fuel tank. 3. Remove the rear fuel feed pipe (4) and the rear fuel return pipe (5) from the fuel sender (2) and the fuel tank clips (6). 4. Cap the fuel pipes in order to prevent possible fuel system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel pipes. 2. Connect the rear fuel feed pipe (4) and the rear fuel return pipe (5) to the fuel sender (2) and the fuel tank clips (6). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 6476 3. Install the fuel tank. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Dual Tanks) Fuel Filler Hose: Service and Repair Filler Tube Replacement (Dual Tanks) REMOVAL PROCEDURE 1. Drain the fuel below the level of the fuel filler hose. Refer to Fuel Tank Draining Procedure (Utility Single Tank) or Fuel Tank Draining Procedure (Utility Dual Tank Front) or Fuel Tank Draining Procedure (Utility Dual Tank Rear). 2. Remove the fuel fill pipe housing to fuel fill pipe bolts. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Disconnect the fuel fill pipe ground strap. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Dual Tanks) > Page 6482 5. Disconnect the rear axle vent hose from the retainer on the fuel fill pipe. 6. Loosen the fuel vent hose (3) to fill tube clamp (2). 7. Disconnect the fuel vent hose (3) from the fill tube. 8. Loosen the fuel fill hose to fuel tank clamp (2). 9. Disconnect the fuel fill hose from the fuel tank. 10. Remove the fuel fill hose assembly. 11. Cap the open end of the fuel tank. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Dual Tanks) > Page 6483 1. Uncap the fuel tank. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel fill hose assembly to the fuel tank. Tighten Tighten the fuel fill pipe clamp (2) to 2.5 N.m (22 lb in). 3. Connect the fuel fill vent hose (3) to the fill tube. Tighten Tighten the vent hose clamp (2) to 2.5 N.m (22 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Dual Tanks) > Page 6484 4. Connect the fuel fill pipe ground strap. Tighten Tighten the fuel fill pipe ground strap bolt to 9 N.m (80 lb in). 5. Connect the rear axle vent hose to the retainer on the fuel fill pipe. 6. Lower the vehicle. 7. Install the fuel fill pipe housing to the fuel fill pipe bolts. Tighten Tighten the fuel fill pipe housing to fuel fill pipe bolts to 2.3 N.m (20 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Dual Tanks) > Page 6485 Fuel Filler Cap 8. Refill the fuel system. 9. Install the fuel filler cap. 10. Connect the negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Dual Tanks) > Page 6486 Fuel Filler Hose: Service and Repair Filler Tube Replacement (Single Tank) REMOVAL PROCEDURE Fuel Filler Cap 1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnection in order to avoid possible contamination of the fuel system. 2. Remove the fuel filler cap. 3. Drain the fuel below the level of the fuel filler hose. Refer to Fuel Tank Draining Procedure (Utility Single Tank) or Fuel Tank Draining Procedure (Utility Dual Tank Front) or Fuel Tank Draining Procedure (Utility Dual Tank Rear). 4. Remove the fuel fill pipe housing to fuel fill pipe bolts. 5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 6. Remove spare tire. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Dual Tanks) > Page 6487 7. Disconnect the fuel fill pipe ground strap (3). 8. Disconnect the rear axle vent hose from the retainer on the fuel fill pipe, if applicable. 9. Loosen the fuel vent hose to fuel tank clamp (1). 10. Loosen the fuel fill hose to fuel tank clamp (11). 11. Disconnect the fuel fill pipe bracket bolt (3). 12. Disconnect the fuel fill and vent hoses from the fuel tank. 13. Remove the fuel fill and vent pipe and hose assembly. 14. Cap the open end of the fuel tank. INSTALLATION PROCEDURE 1. Uncap the fuel tank. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Dual Tanks) > Page 6488 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel fill and vent pipe hose assembly to the fuel tank. Tighten Tighten the vent hose clamp (1) and the fuel fill pipe clamp (11) to 2.5 N.m (22 lb in) 3. Install the fuel fill pipe bracket bolt (3). Tighten Tighten the bolt to 12 N.m (106 lb in). 4. Connect the fuel fill pipe ground strap (3). Tighten Tighten the fuel fill pipe ground strap bolt to 9 N.m (80 lb in). 5. Connect the rear axle vent hose to the retainer on the fuel fill pipe, if applicable. 6. Install spare tire. 7. Lower the vehicle. 8. Install the fuel fill pipe housing to the fuel fill pipe bolts. Tighten Tighten the fuel fill pipe housing to fuel fill pipe bolts to 2.3 N.m (20 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Dual Tanks) > Page 6489 Fuel Filler Cap 9. Refill the fuel system. 10. Install the fuel filler cap. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Dual Tanks) > Page 6490 Fuel Filler Hose: Service and Repair Fuel Filler Hose Replacement REMOVAL PROCEDURE 1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in order to avoid possible contamination of the fuel system. 2. Drain the fuel below the level of the filler tube and hose assembly. Refer to Fuel Tank Draining Procedure (Utility Single Tank) or Fuel Tank Draining Procedure (Utility Dual Tank Front) or Fuel Tank Draining Procedure (Utility Dual Tank Rear) 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Disconnect the fuel fill hose clamp (11) at the fuel tank. 5. Disconnect the fuel fill hose clamp (2) at the fuel till pipe. 6. Remove the fuel fill hose and the hose clamps (11, 2). 7. Disconnect the fuel till hose clamp (8) at the fill pipe. 8. Disconnect the fuel fill hose clamp (10) at the fill pipe. 9. Remove the fuel till hose and the hose clamps (8, 10). 10. Cap the fuel tank opening. INSTALLATION PROCEDURE 1. Uncap the fuel tank opening. 2. Install the fuel fill hose and the hose clamps (8,10) to the fuel fill pipe. 3. Install the fuel fill hose and the hose clamps (2,11) to the fuel fill pipe. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the hose clamps to 2.5 N.m (22 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement (Dual Tanks) > Page 6491 4. Lower the vehicle. 5. Refill the fuel system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: Customer Interest Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge > Page 6500 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge > Page 6501 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge > Page 6507 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge > Page 6508 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6509 Fuel Gauge Sender: Specifications Fuel Level Specifications Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6510 Fuel Level Specifications Part 2 The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6511 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6512 Fuel Gauge Sender: Diagrams Fuel Pump/Sender - Secondary Fuel Pump/Sender - Primary Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6513 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The Powertrain Control Module (PCM) sends the fuel level information via the class 2 circuit to the Instrument Panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6514 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the retaining clip (6) from the fuel level sensor connector. 4. Disconnect the electrical connector (7) from under the fuel sender cover. 5. Remove the sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip (4). 3. Connect the electrical connector (7) to the fuel level sensor. 4. Connect the retaining clip (6) to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams Fuel Tank Unit: Diagrams Fuel Pump And Sender-Secondary Fuel Pump And Sender-Primary Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 6518 Fuel Tank Unit: Service and Repair Fuel Sender Assembly Replacement Tool Required J44402 Fuel Tank Sending Unit Wrench. Removal Procedure 1. Remove the fuel tank. 2. Remove fuel lines from sender assembly. 3. Remove the fuel sender assembly retaining ring using the J 44402. 4. Remove the fuel sender assembly and the seal. Discard the seal. Caution: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. 5. Clean the fuel sender sealing surfaces. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 6519 Caution: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. 1. Install the new seal on the fuel tank. Important: The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm. 2. Install the fuel sender assembly into the fuel tank. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Install the fuel sender assembly retaining ring using the J 44402. 4. Install fuel lines to sender assembly.. 5. Install the fuel tank. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 6523 Idle Air Control (IAC) Valve Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 6524 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection CIRCUIT DESCRIPTION The engine idle speed is controlled by the idle air control (IAC) valve. The IAC valve is on the throttle body. The IAC valve pintle moves in and out of an idle air passage bore to control air flow around the throttle plate. The valve consists of a movable pintle, driven by a gear attached to a two phase bi-polar permanent magnet electric motor called a stepper motor. The stepper motor is capable of highly accurate rotation, or of movement, called steps. The stepper motor has two separate windings that are called coils. Each coil is fed by two circuits from the powertrain control module (PCM). When the PCM changes polarity of a coil, the stepper motor moves one step. The PCM uses a predetermined number of counts to determine the IAC pintle position. Observe IAC counts with a scan tool. The IAC counts will increment up or down as the PCM attempts to change the IAC valve pintle position. An IAC Reset will occur when the ignition key is turned OFF. First, the PCM will seat the IAC pintle in the idle air passage bore. Second, the PCM will retract the pintle a predetermined number of counts to allow for efficient engine start-up. If the engine idle speed is out of range for a calibrated period of time, an idle speed diagnostic trouble code (DTC) may set. DIAGNOSTIC AIDS Inspect for the following conditions: ^ A skewed high throttle position (TP) sensor ^ Restricted air intake system ^ Objects blocking the IAC passage or throttle bore ^ The correct positive crankcase ventilation (PCV) valve ^ A properly installed PCV valve ^ Proper operation of the PCV valve ^ Proper operation and installation of all air intake components ^ Proper installation and operation of the mass air flow (MAF) sensor, if equipped ^ Evidence of damage or tampering of the following components: The throttle stop screw - The throttle plate - The throttle shaft - The throttle linkage - The cruise control linkage-if equipped ^ Excess deposits in the IAC passage or on the IAC pintle ^ Excess deposits in the throttle bore or on the throttle plate ^ Vacuum leaks ^ Excess load on engine, such as energy-draining conditions of the transmission, power steering, or alternator ^ A high or unstable idle condition-This condition could be caused by a non-IAC system problem that can not be overcome by the IAC valve. Refer to Symptoms - Computers and Controls Systems. See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures ^ A low or unstable idle condition-This condition could be caused by a non-IAC system problem that can not be overcome by the IAC valve. Refer to Symptoms - Computers and Controls Systems. See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures ^ An intermittent condition-If the condition is intermittent, refer to Intermittent Conditions. See: Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Intermittent Conditions TEST DESCRIPTION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 6525 Steps 1-6 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 6526 Steps 7-11 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 6527 Steps 12-19 The numbers below refer to the step numbers on the diagnostic table. 5. This test will determine the ability of the PCM and IAC valve circuits to control the IAC valve. 7. This test will determine the ability of the PCM to provide the IAC valve circuits with a ground. On a normally operating system, the test lamp should not flash while the IAC counts are incrementing. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 6528 Idle Speed/Throttle Actuator - Electronic: Service and Repair IDLE AIR CONTROL (IAC) VALVE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the idle air control (IAC) valve electrical connector 2. Remove the IAC valve attaching screws (4). 3. Remove the IAC valve (3). 4. Remove the IAC valve O-ring seal (2). NOTE: ^ Do Not push or pull on the IAC valve pintle on IAC valves that have been in service. The force required to move the pintle may damage the threads on the worm drive. ^ Do Not soak the IAC valve in any liquid cleaner or solvent, as damage may result. 5. Clean the IAC valve O-ring sealing surface, the pintle valve seat, and the air passage. ^ Clean the IAC valve using GM cleaner P/N 1052626 or GM X-66A. Use a shop towel or parts brush to remove heavy deposits. ^ If the air passage has heavy deposits, remove the throttle body for complete cleaning. ^ Shiny spots on the pintle or seat are normal and do not indicate misalignment or a bent pintle shaft. 6. Inspect the IAC valve O-ring for cuts, cracks, or distortion. Replace the O-ring if the O-ring is damaged. INSTALLATION PROCEDURE IMPORTANT: If installing a new IAC valve, be sure to replace the IAC valve with an identical part. The pintle shape of the IAC valve and the diameter of the IAC valve are designed for the specific application. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 6529 1. Measure the distance between the tip of the IAC valve pintle and the mounting surface (1). If the distance is more than 28 mm (1.1 in) use finger pressure to slowly retract the pintle. The force required to retract the pintle of a new valve does not cause damage to the valve. 2. Lubricate the IAC valve O-ring (2) with clean engine oil. 3. Install the IAC valve O-ring (2) on the IAC valve (3). 4. Install the IAC valve (3). 5. Apply LOCTITE 262 to the IAC valve attaching screw threads if necessary. NOTE: Refer to the Fastener Notice in Service Precautions. 6. Install the IAC valve attaching screws (4). Tighten Tighten the screws to 3 N.m (27 lb in). 7. Connect the IAC valve electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Plenum > Intake Air Plenum Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Air Plenum Gasket: > 05-06-04-029A > Jun > 05 > Engine - Rough Idle/Misfire/MIL ON/DTC P0300 Intake Air Plenum Gasket: Customer Interest Engine - Rough Idle/Misfire/MIL ON/DTC P0300 Bulletin No.: 05-06-04-029A Date: June 24, 2005 TECHNICAL Subject: Flexible Fuel (RPO L59) Rough Idle, Misfire, MIL DTC P0300 (Install Intake Manifold Gaskets With Teal Green Gasket Material) Models: 2002-2004 Chevrolet Silverado, Suburban, Tahoe 2002-2004 GMC Sierra, Yukon, Yukon XL with 5.3L Engine and Flexible Fuel (VIN Z - RPO L59) This bulletin may apply to the following engines using regular fuel: 4.8L, 5.3L, 6.0L (VINs V, T, P, U, N - RPOs LR4, LM7, LM4, LQ4, LQ9). Supercede: This bulletin is being revised to add additional diagnostic information. Please discard Corporate Bulletin Number 05-06-04-029 (Section 06 - Engine/Propulsion System). Important: Always begin your diagnosis with the Diagnostic System Check - Engine Controls (SI Document ID # 1289827) for any MIL or driveability concern. The Diagnostic System Check directs you to the next logical step in your diagnosis. Follow the instructions in this bulletin should the rough idle, misfire, or DTC P0300 diagnostic procedure point to an air leak in the intake manifold gasket. Following the published diagnostic procedures will improve diagnostic accuracy and support our fix it right the first time approach. Condition Some customers may comment that the vehicle may have a rough idle, misfires and/or a MIL illuminated with a stored DTC P0300. Cause The L59 engine is calibrated for ethanol fuel (E85). Due to the low volatility of ethanol, the PCM provides higher fuel flow through the injector, which may pool on the upper manifold to head gasket material. Overtime (usually 12 months and longer), the gasket material may degrade resulting in an unmetered air leak. Correction Replace the upper intake manifold gaskets with the teal green gasket material, P/N 89017589. Important: Do not replace the upper intake manifold gaskets with the original orange gasket material, P/N 17113557. Inspect Intake Manifold to Cylinder head Deck for Warpage Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Plenum > Intake Air Plenum Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Air Plenum Gasket: > 05-06-04-029A > Jun > 05 > Engine - Rough Idle/Misfire/MIL ON/DTC P0300 > Page 6539 Important: The intake plenum should also be checked for excessive warpage that may cause an uneven clamping pressure of the seal. If the plenum is found to be warped it will need to be replaced. Service Information states, "An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area should be replaced." Intake warpage is measured at the gasket sealing surfaces and should be measured within a 200 mm (7.87 in) area. This measurement is across only two of the intake runner port openings. Measurements taken across the entire distance of all four intake runner ports will lead to unnecessary manifold replacements. Important: Measurements taken across the entire distance of all four intake runner ports will lead to unnecessary intake manifold replacements. 1. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across two runner port openings. 2. Insert a feeler gauge between the intake manifold and the straight edge. An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced. Do not replace intake manifolds with warpage that measures less than 3 mm (0.118 in) over a 200 mm (7.87 in). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Plenum > Intake Air Plenum Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Air Plenum Gasket: > 05-06-04-029A > Jun > 05 > Engine - Rough Idle/Misfire/MIL ON/DTC P0300 > Page 6540 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Plenum > Intake Air Plenum Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Air Plenum Gasket: > 05-06-04-029A > Jun > 05 > Engine - Rough Idle/Misfire/MIL ON/DTC P0300 Intake Air Plenum Gasket: All Technical Service Bulletins Engine - Rough Idle/Misfire/MIL ON/DTC P0300 Bulletin No.: 05-06-04-029A Date: June 24, 2005 TECHNICAL Subject: Flexible Fuel (RPO L59) Rough Idle, Misfire, MIL DTC P0300 (Install Intake Manifold Gaskets With Teal Green Gasket Material) Models: 2002-2004 Chevrolet Silverado, Suburban, Tahoe 2002-2004 GMC Sierra, Yukon, Yukon XL with 5.3L Engine and Flexible Fuel (VIN Z - RPO L59) This bulletin may apply to the following engines using regular fuel: 4.8L, 5.3L, 6.0L (VINs V, T, P, U, N - RPOs LR4, LM7, LM4, LQ4, LQ9). Supercede: This bulletin is being revised to add additional diagnostic information. Please discard Corporate Bulletin Number 05-06-04-029 (Section 06 - Engine/Propulsion System). Important: Always begin your diagnosis with the Diagnostic System Check - Engine Controls (SI Document ID # 1289827) for any MIL or driveability concern. The Diagnostic System Check directs you to the next logical step in your diagnosis. Follow the instructions in this bulletin should the rough idle, misfire, or DTC P0300 diagnostic procedure point to an air leak in the intake manifold gasket. Following the published diagnostic procedures will improve diagnostic accuracy and support our fix it right the first time approach. Condition Some customers may comment that the vehicle may have a rough idle, misfires and/or a MIL illuminated with a stored DTC P0300. Cause The L59 engine is calibrated for ethanol fuel (E85). Due to the low volatility of ethanol, the PCM provides higher fuel flow through the injector, which may pool on the upper manifold to head gasket material. Overtime (usually 12 months and longer), the gasket material may degrade resulting in an unmetered air leak. Correction Replace the upper intake manifold gaskets with the teal green gasket material, P/N 89017589. Important: Do not replace the upper intake manifold gaskets with the original orange gasket material, P/N 17113557. Inspect Intake Manifold to Cylinder head Deck for Warpage Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Plenum > Intake Air Plenum Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Air Plenum Gasket: > 05-06-04-029A > Jun > 05 > Engine - Rough Idle/Misfire/MIL ON/DTC P0300 > Page 6546 Important: The intake plenum should also be checked for excessive warpage that may cause an uneven clamping pressure of the seal. If the plenum is found to be warped it will need to be replaced. Service Information states, "An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area should be replaced." Intake warpage is measured at the gasket sealing surfaces and should be measured within a 200 mm (7.87 in) area. This measurement is across only two of the intake runner port openings. Measurements taken across the entire distance of all four intake runner ports will lead to unnecessary manifold replacements. Important: Measurements taken across the entire distance of all four intake runner ports will lead to unnecessary intake manifold replacements. 1. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across two runner port openings. 2. Insert a feeler gauge between the intake manifold and the straight edge. An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced. Do not replace intake manifolds with warpage that measures less than 3 mm (0.118 in) over a 200 mm (7.87 in). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Plenum > Intake Air Plenum Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Air Plenum Gasket: > 05-06-04-029A > Jun > 05 > Engine - Rough Idle/Misfire/MIL ON/DTC P0300 > Page 6547 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay Fuel Pump Relay: Locations Fuel Pump Relay FUEL PUMP RELAY Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 6553 Locations View The Fuel Pump (FP) Relay is located in the Underhood Fuse Block. The Underhood Fuse Block is located at the left side of the engine compartment near the battery. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 6554 Fuel Pump Relay: Locations Fuel Pump Relay Secondary - With Dual Tanks SECONDARY FUEL PUMP RELAY (With Dual Tanks Only) Locations View The Secondary Fuel Pump (FP) Relay (1) is attached to the Underhood Fuse Block on bracket. The Underhood Fuse Block is located at the left side of the engine compartment near the battery. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuel Pump Relay > Page 6555 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6558 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6559 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6560 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6561 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6562 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6563 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6564 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6565 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6566 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6567 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6568 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6569 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6570 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6571 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6572 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6573 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6574 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6575 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6576 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6577 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6578 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6579 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6580 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6581 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6582 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6583 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6584 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6585 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6586 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6587 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6588 Fuel Pump (FP) Relay-Secondary Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Resonator, Intake Air > Component Information > Service and Repair Resonator: Service and Repair REMOVAL PROCEDURE 1. Loosen the clamp and separate the air cleaner resonator outlet duct from the mass air flow/intake air temperature (MAF/IAT) sensor assembly. 2. Loosen the clamp and separate the air cleaner resonator outlet duct from the throttle body assembly. 3. Remove the air cleaner resonator outlet duct. INSTALLATION PROCEDURE 1. Install the air cleaner resonator outlet duct to the throttle body assembly and the MAF/IAT sensor assembly. 2. Tighten the clamps at the throttle body assembly and the MAF/IAT sensor assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6596 Accelerator Pedal Position (APP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6597 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position (APP) Sensor The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 3 individual accelerator pedal position sensors within one housing. Three separate signal, low reference, and 5-volt reference circuits are used to connect the APP and the TAC module. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 1.0 volt at 0 pedal travel to above 2.0 volts at 100 percent pedal travel. APP sensor 2 voltage should decrease from above 4.0 volts at 0 pedal travel to below 2.9 volts at 100 percent pedal travel. APP sensor 3 voltage should decrease from above 3.8 volts at 0 percent pedal travel to below 3.1 volts at 100 percent pedal travel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6598 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the left instrument panel (IP) lower closeout insulator panel. 2. Disconnect the accelerator pedal position (APP) sensor harness connector. Remove the accelerator pedal mounting bolts. 3. Remove the APP assembly. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6599 1. Install the APP assembly to the steering column support bracket. NOTE: Refer to the Fastener Notice in Service Precautions. IMPORTANT: Always use a torque wrench in order to obtain the proper torque. 2. Install the accelerator pedal mounting bolts. Tighten Tighten the accelerator pedal mounting bolts to 20 N.m (15 lb ft). 3. Connect the APP sensor harness connector. 4. Verify that the vehicle meets the following conditions: ^ The vehicle is not in a Reduced Engine Power mode. ^ The ignition is ON. ^ The engine is OFF. 5. Connect a scan tool in order to test for a proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Inspect the carpet fit under the accelerator pedal. 8. Install the left IP lower closeout insulator panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6605 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6606 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6607 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6608 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6609 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6610 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6611 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6612 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6613 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6614 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6615 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6616 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6617 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6618 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6619 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6620 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6621 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6622 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6623 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6624 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6625 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6626 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6627 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6628 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6629 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6630 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6631 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6632 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6633 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6634 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6635 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 6636 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Take care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. Do not drop or roughly handle the MAF/IAT sensor. 1. Remove air intake resonator. 2. Disconnect the MAF/IAT sensor electrical connector. 3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 6637 2. Install the MAF/IAT sensor on to the air cleaner housing. 3. Tighten the clamp securing the MAF/IAT sensor to the air cleaner housing. 4. Connect the MAF/IAT electrical connector. 5. Install air intake resonator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams Fuel Composition Sensor - W/L59 Only Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 6641 Flexible Fuel Sensor: Description and Operation FUEL COMPOSITION SENSOR DESCRIPTION The Fuel Composition Sensor (FCS), or flex fuel sensor (service parts term), measures the ethanol-gasoline ratio of the fuel being used in a flexible fuel vehicle. Flexible fuel vehicles can be operated with a blend of ethanol and gasoline, up to 85 percent ethanol. In order to adjust the ignition timing and the fuel quantity to be injected, the engine management system requires information about the percentage of ethanol in the fuel. The FCS uses quick-connect style fuel connections, an incoming fuel connection, and an outgoing fuel connection. The two connections have different diameters, to prevent incorrect attachment of the fuel lines. All fuel passes through the fuel composition sensor before continuing on to the fuel rail. The fuel composition sensor measures two different fuel related parameters, and sends an electrical signal to the Powertrain Control Module (PCM) to indicate ethanol percentage, and fuel temperature. The fuel composition sensor has a three-wire electrical harness connector. The three wires provide a ground circuit, a power source, and a signal output to the PCM. The power source is vehicle system voltage, +12 volts), and the ground circuit connects to chassis ground. The signal circuit carries both the ethanol percentage and fuel temperature within the same signal, on the same wire. The FCS uses a microprocessor inside the sensor to measure the ethanol percentage and fuel temp, and change an output signal accordingly. The electrical characteristic of the FCS signal is a square-wave digital signal. The signal is both variable frequency and variable pulse width. The frequency of the signal indicates the ethanol percentage, and the pulse width indicates the fuel temperature. The PCM provides an internal pull-up to five volts on the signal circuit, and the FCS pulls the 5 volts to ground in pulses. The output frequency is linear to the percentage of ethanol content in the fuel. The normal range of operating frequency is between 50 and 150 Hertz, with 50 Hertz representing 0 percent ethanol, and 150 Hertz representing 100 percent ethanol. The normal pulse width range of the digital pulses is between 1 and 5 milliseconds, with 1 millisecond representing 40°C (-40°F), and 5 milliseconds representing 125°C (257°F). The microprocessor inside the sensor is capable of a certain amount of self-diagnosis. An output frequency of 170 Hertz indicates either that the fuel is contaminated or contains methanol (it should not), or that an internal sensor electrical fault has been detected. Certain substances dissolved in the fuel can cause the fuel to be contaminated, raising the output frequency to be higher than the actual ethanol percentage should indicate. Examples of these substances include water, sodium chloride (salt), and methanol. It should be noted that it is likely that the FCS will indicate a slightly lower ethanol percentage than what is advertised at the fueling station. This is not a fault of the sensor. The reason has to do with government requirements for alcohol-based motor fuels. Government regulations require that alcohol intended for use as motor fuel be DENATURED. This means that 100 percent pure ethanol is first denatured with approximately 4% percent gasoline, before being mixed with anything else. When an ethanol gasoline mixture is advertised as E85, the 85 percent ethanol was denatured before being blended with gasoline, meaning an advertised E85 fuel contains only about 81 percent ethanol. The FCS measures the actual percentage of ethanol in the fuel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 6642 Flexible Fuel Sensor: Service and Repair FUEL COMPOSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure. 3. Raise the vehicle. 4. Remove the fuel composition sensor fuel composition sensor (FCS) attachment nuts (1). 5. Disconnect the FCS inlet and outlet pipes from the FCS. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 6643 6. Disconnect the FCS electrical connector (1). 7. Remove the FCS and bracket assembly from the frame rail. 8. Remove the FCS bolts and remove from the bracket. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 6644 1. Install the FCS to the bracket and install bolts. Tighten Tighten bolts to 10 N.m (89 lb in). 2. Install FCS and bracket assembly to frame. 3. Install FCS bracket to frame nuts. Tighten Tighten nuts (1) to 17 N.m (13 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Flexible Fuel Sensor > Component Information > Diagrams > Page 6645 4. Connect the FCS inlet and outlet pipes to the FCS. 5. Connect the FCS electrical connector (1). 6. Lower the vehicle. 7. Start the engine and check for fuel leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6651 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6652 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6653 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6654 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6655 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6656 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6657 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6658 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6659 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6660 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6661 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6662 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6663 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6664 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6665 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6666 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6667 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6668 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6669 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6670 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6671 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6672 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6673 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6674 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6675 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6676 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6677 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6679 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6680 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6681 Throttle Position Sensor: Connector Views Throttle Position (TP) Sensor Throttle Position (TP) Sensor (Dual Track) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 6682 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to the Battery Disconnect Caution in Service Precautions. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result. IMPORTANT: If the vehicle is equipped with electronic throttle control (ETC) the throttle position (TP) sensor is NOT serviceable. The throttle body and TP sensor MUST be serviced as a complete assembly. 1. Disconnect the negative battery cable. 2. Remove the generator. 3. Disconnect the throttle position TP sensor electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 6683 4. Remove the TP sensor attaching screws (5). 5. Remove the TP sensor (6). 6. Remove the TP sensor O-ring seal (7). INSTALLATION PROCEDURE 1. Install the TP sensor O-ring seal (7) on the TP sensor (6). 2. Install the TP sensor on the throttle body with the throttle valve in the closed position. Verify the TP sensor lever lines up with the TP sensor drive lever on the throttle shaft. NOTE: Refer to the Fastener Notice in Service Precautions. 3. Install the TP sensor attaching screws (5). Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 6684 4. Connect the TP sensor electrical connector. 5. Install the generator. 6. Connect the negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 04-06-04-040 > Jun > 04 > Fuel System Low/Rough or Unstable Idle Throttle Body: Customer Interest Fuel System - Low/Rough or Unstable Idle Bulletin No.: 04-06-04-040 Date: June 14, 2004 TECHNICAL Subject: Idle Instability, Low or Rough Idle with Electronic Throttle Control (Clean Throttle Body) Models: 2002-2003 Cadillac Escalade, Escalade EXT 2000-2003 Chevrolet Silverado, Suburban, Tahoe 2002-2003 Chevrolet Avalanche 2000-2003 GMC Sierra, Yukon, Yukon XL with 4.8L, 5.3L or 6.0L V8 Engine (VINs V, T, Z, N, U - RPOs LR4, LM7, L59, LQ9, LQ4) and Electronic Throttle Control Condition Some owners may comment on an idle instability, low idle speed or rough idle. Cause Condition may be caused by deposits in the throttle body bore. Correction Clean throttle body bore and throttle valve plate of carbon using a shop rag and an appropriate cleaner. Refer to Engine Controls Repair Procedures - Throttle Body Cleaning Procedure. This procedure may be performed at any mileage necessary. Check to determine if the PCM calibration has been previously updated to one that includes the update for throttle body coking. For 2003 model year vehicles, look in the operating system portion of the calibration. For 2000-2002 model year vehicles, look in the engine portion of the calibration. If not, then update the PCM calibration to the latest calibration. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 04-06-04-040 > Jun > 04 > Fuel System - Low/Rough or Unstable Idle Throttle Body: All Technical Service Bulletins Fuel System - Low/Rough or Unstable Idle Bulletin No.: 04-06-04-040 Date: June 14, 2004 TECHNICAL Subject: Idle Instability, Low or Rough Idle with Electronic Throttle Control (Clean Throttle Body) Models: 2002-2003 Cadillac Escalade, Escalade EXT 2000-2003 Chevrolet Silverado, Suburban, Tahoe 2002-2003 Chevrolet Avalanche 2000-2003 GMC Sierra, Yukon, Yukon XL with 4.8L, 5.3L or 6.0L V8 Engine (VINs V, T, Z, N, U - RPOs LR4, LM7, L59, LQ9, LQ4) and Electronic Throttle Control Condition Some owners may comment on an idle instability, low idle speed or rough idle. Cause Condition may be caused by deposits in the throttle body bore. Correction Clean throttle body bore and throttle valve plate of carbon using a shop rag and an appropriate cleaner. Refer to Engine Controls Repair Procedures - Throttle Body Cleaning Procedure. This procedure may be performed at any mileage necessary. Check to determine if the PCM calibration has been previously updated to one that includes the update for throttle body coking. For 2003 model year vehicles, look in the operating system portion of the calibration. For 2000-2002 model year vehicles, look in the engine portion of the calibration. If not, then update the PCM calibration to the latest calibration. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 6698 Throttle Body: Specifications Throttle Body Nuts ............................................................................................................................... ................................................. 10 Nm (89 inch lbs.) Throttle Body Studs .......................................... ..................................................................................................................................... 6 Nm (53 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 6699 Throttle Body: Description and Operation Throttle Body Assembly The throttle body for the TAC system is similar to a conventional throttle body with a couple of exceptions. One exception being the use of a motor to control the TP instead of a mechanical cable. The other exception is the new design TP sensor. The TP sensor mounts on the side of the throttle body opposite the throttle actuator motor. The TP sensor is actually 2 individual TP sensors within one housing. Separate signal, low reference, and 5-volt reference circuits are used to connect the TP sensors and the TAC module. The TP sensor 1 signal voltage increases as the throttle opens, from around 1.0 volt at 0 throttle to above 3.5 volts at 100 percent throttle. TP sensor 2 signal voltage decreases as the throttle is opened, from around 3.8 volts at 0 throttle to below 1.0 volt at 100 percent throttle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement (W/O ETC) Throttle Body: Service and Repair Throttle Body Assembly Replacement (W/O ETC) REMOVAL PROCEDURE 1. Remove the air intake duct. 2. Disconnect the accelerator control cable and the cruise control cable from the throttle body. 3. Disconnect the vacuum hose from the throttle body. 4. Disconnect the throttle position (TP) sensor and idle air control (IAC) valve harness connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement (W/O ETC) > Page 6702 5. Disconnect the coolant hose from the throttle body. 6. Disconnect the coolant hose from the vapor vent pipe. 7. Remove the throttle body attaching nuts. 8. Remove the throttle body and the gasket. Discard the gasket. NOTE: In order to prevent damage to the sealing surfaces, carefully use sharp tools in cleaning the old gasket from the aluminum surfaces. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement (W/O ETC) > Page 6703 IMPORTANT: DO NOT soak the throttle body in a cold immersion type cleaner. The throttle plate has a factory applied sealing compound. DAG material is applied to the outside edge of the plate and the throttle bore to prevent air bypass at closed throttle. Strong solvents or brushing removes the material. To clean the throttle body following disassembly, use a spray type cleaner such as GM X-66A or GM P/N 1052626. Use a shop towel to remove heavy deposits. - The TP sensor and the IAC valve are electrical components, and should NOT come in contact with solvent or cleaner in order to avoid damage. 9. Clean the gasket sealing surfaces. INSTALLATION PROCEDURE 1. Install the throttle body with a new gasket. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the throttle body attaching nuts. Tighten Tighten the nuts to 10 N.m (89 lb in). 3. Connect the coolant hose to the throttle body. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement (W/O ETC) > Page 6704 4. Connect the coolant hose to the vapor vent pipe. 5. Connect the accelerator control cable and the cruise control cable to the throttle body. 6. Connect the TP sensor and the IAC valve electrical connectors. 7. Connect the vacuum hose to the throttle body. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement (W/O ETC) > Page 6705 8. Install the air intake duct. 9. With the engine OFF, verify that the accelerator pedal moves freely. Depress the accelerator pedal to the floor and release the pedal. 10. In order to reset the IAC valve, perform the following procedure: 10.1. Turn ON the ignition for 10 seconds. 10.2. Turn OFF the ignition for 5 seconds. 10.3. Start the engine and check for the proper idle speed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement (W/O ETC) > Page 6706 Throttle Body: Service and Repair Throttle Body Assembly Replacement (W/ ETC) REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. IMPORTANT: An eight digit part identification number is stamped on the throttle body casting. Refer to this number if servicing, or part replacement is required. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Partially drain the cooling system in order to allow the hoses at the throttle body to be removed. Refer to Draining and Filling Cooling System in Cooling System. 3. Lower the vehicle. IMPORTANT: Cover or plug any openings when servicing the throttle body in order to prevent possible contamination. 4. Remove the air intake duct. 5. Disconnect the throttle actuator motor harness connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement (W/O ETC) > Page 6707 6. Disconnect the throttle position (TP) and intake air control (IAC) sensor harness connector. 7. Disconnect the crankcase ventilation hose from the throttle body. 8. Remove the throttle body attaching bolts. 9. Disconnect the coolant hoses from the throttle body. 10. Remove the throttle body and the gasket. IMPORTANT: Do not reuse the throttle body gasket. Install a new gasket during assembly. 11. Discard the throttle body gasket. 12. Inspect the crankcase ventilation hose and the tube. Replace any damaged components. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement (W/O ETC) > Page 6708 1. Install a new throttle body gasket. 2. Connect the coolant hoses to the throttle body. 3. Install the throttle body assembly. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Always use a torque wrench in order to obtain the proper torque. 4. Install the throttle body attaching bolts. Tighten Tighten the throttle body bolts to 10 N.m (89 lb in). 5. Connect the TP and IAC sensor harness connector. 6. Connect the crankcase ventilation hose to the throttle body. IMPORTANT: Verify that the throttle actuator motor harness connector and the connector seal are properly installed and not damaged. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement (W/O ETC) > Page 6709 7. Connect the throttle actuator motor harness connector. 8. Install the air intake duct. 9. Connect the intake air temperature sensor harness connector. 10. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 11. Verify that the vehicle meets the following conditions: - The vehicle is not in a Reduced Engine Power mode. - The ignition is ON. - The engine is OFF. 12. Connect a scan tool in order to test for a proper throttle-opening and throttle-closing range. 13. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 14. Start the engine. 15. Inspect for coolant leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement (W/O ETC) > Page 6710 Throttle Body: Service and Repair Throttle Body Cleaning Procedure IMPORTANT: Over extended time and mileage, deposits may accumulate on the back of the throttle valve plate. The source of the deposit is exhaust gas recirculation (EGR) gas. Typically these deposits pose no problem. Occasionally the deposit may accumulate to a point where perceived pedal effort or throttle valve movement is effected. This procedure should not be performed on vehicles with mileage under 80450 km (50,000 mi). 1. Remove the air intake duct. CAUTION: Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement of the throttle blade could cause personal injury. NOTE: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. 2. Inspect the throttle body bore and the throttle valve plate for deposits. You will need to open the throttle valve in order to inspect all surfaces. NOTE: Do not use any solvent that contains Methyl Ethyl ketone (MEK). This solvent may damage fuel system components. 3. Clean the throttle body bore and the throttle valve plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626 or AC-Delco Carburetor Tune-Up Conditioner, P/N X66-P, or an equivalent product. 4. Install the air intake duct. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair ACCELERATOR CONTROLS CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the accelerator cable from the throttle body lever. 3. Remove the accelerator cable from the cable bracket. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 6714 4. Unclip the accelerator cable from the engine sight shield mounting bracket. 5. Remove the left instrument panel (IP) insulator. 6. Disconnect the accelerator cable retainer (3) from the accelerator pedal lever (2). 7. Squeeze the accelerator cable cover tangs (1) and push the cable through the dash panel. 8. Remove the accelerator cable. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 6715 1. Install the accelerator cable through the dash panel. Snap the accelerator cable cover tangs (1) through the dash panel. 2. Install the accelerator cable through the slot in the accelerator pedal lever (2). 3. Seat the retainer (3) in the accelerator pedal lever (2). 4. Connect the accelerator cable to the throttle body lever. 5. Slide the accelerator cable into the slot on the accelerator cable bracket. Snap the locking tab into position. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 6716 6. Clip the accelerator cable into the engine sight shield mounting bracket. 7. Test for complete throttle opening and closing range by operating the accelerator pedal. Also inspect the carpet fit under the accelerator pedal. The throttle should operate freely without binding between full closed throttle and wide open throttle (WOT). 8. Install the left IP insulator. 9. Install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6740 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6746 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6748 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6749 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6750 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6751 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 Throttle Position Sensor: Connector Views Throttle Position (TP) Sensor Throttle Position (TP) Sensor (Dual Track) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 6753 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to the Battery Disconnect Caution in Service Precautions. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result. IMPORTANT: If the vehicle is equipped with electronic throttle control (ETC) the throttle position (TP) sensor is NOT serviceable. The throttle body and TP sensor MUST be serviced as a complete assembly. 1. Disconnect the negative battery cable. 2. Remove the generator. 3. Disconnect the throttle position TP sensor electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 6754 4. Remove the TP sensor attaching screws (5). 5. Remove the TP sensor (6). 6. Remove the TP sensor O-ring seal (7). INSTALLATION PROCEDURE 1. Install the TP sensor O-ring seal (7) on the TP sensor (6). 2. Install the TP sensor on the throttle body with the throttle valve in the closed position. Verify the TP sensor lever lines up with the TP sensor drive lever on the throttle shaft. NOTE: Refer to the Fastener Notice in Service Precautions. 3. Install the TP sensor attaching screws (5). Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 6755 4. Connect the TP sensor electrical connector. 5. Install the generator. 6. Connect the negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6780 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6781 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6782 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6783 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6784 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6785 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6786 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6787 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6788 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6789 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6790 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6791 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6792 Camshaft Position (CMP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 6793 Camshaft Position Sensor: Description and Operation The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 6794 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. Camshaft Position Sensor (CMP) 1. Remove the engine sight shield, as necessary. 2. Disconnect the CMP sensor electrical connector. 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor. INSTALLATION PROCEDURE Camshaft Position Sensor (CMP) 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CMP sensor electrical connector. 4. Install the engine sight shield, as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6800 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6801 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6802 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6803 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6805 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6806 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6807 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6808 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6809 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6810 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6811 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6812 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6813 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6814 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6815 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6816 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6817 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6818 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6819 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6820 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6821 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6822 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6823 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6824 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6825 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6826 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6827 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6828 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6829 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6830 Crankshaft Position (CKP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 6831 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at Top Dead Center (TDC). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module (PCM) for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. Observe the fuel cut-off for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: ^ Block the drive wheels. ^ Apply the vehicles parking brake. ^ Cycle the ignition from OFF to ON. ^ Apply and hold the brake pedal. ^ Start and idle the engine. ^ Turn OFF the AC. ^ Place the vehicle's transmission in Park (A/T) or Neutral (M/T). ^ The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. With the scan tool, enable the CKP system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-off is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine Mechanical. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 6834 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure when the crankshaft position sensor is removed or replaced. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the starter. 4. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 6835 5. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 6. Remove the CKP sensor retaining bolt. 7. Remove the CKP sensor. INSTALLATION PROCEDURE Crankshaft Position Sensor (CKP) 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor retaining fastener. Tighten Tighten the bolt to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 6836 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Ignition System Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection Ignition Cable: Service and Repair Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: ^ Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. ^ Any signs of cracks or splits in the wires. ^ Inspect each boot for the following conditions: Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 6842 Ignition Cable: Service and Repair Spark Plug Wire Replacement REMOVAL PROCEDURE 1. Disconnect the spark plug wire at each spark plug. ^ Twist each spark plug 1/2 turn. ^ Pull only on the boot in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the ignition coil. ^ Twist each spark plug boot 1/2 turn. ^ Pull only on the boot in order to remove the wires from the ignition coil. SPARK PLUG WIRE LENGTH V8 Spark Plug Wire Length V8 ^ The Melco(R), square design, uses a spark plug wire (1) that is 145 mm (5.70 in) length cable seal to cable seal. ^ The Delphi(R), round design uses a spark plug wire (2) that is 110 mm (4.30 in) length cable seal to cable seal. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 6843 Ignition Coils ^ There are 2 different manufacturers for the ignition coils, the Melco(R) (1) square design, and the Delphi(R) (2) round design. These 2 coils use 2 different spark plug wire, and mounting brackets. ^ Melco(R), square design, coil mounting bracket (1). ^ Delphi(R), round design, coil mounting bracket (2). INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 6844 1. Install the spark plug wires at the ignition coil. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: ^ Push sideways on each boot in order to inspect the seating. ^ Reinstall any loose boot. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams Ignition Coil: Diagrams Ignition Coil/Driver - Cylinder 1 Ignition Coil/Driver - Cylinder 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 6848 Ignition Coil/Driver - Cylinder 3 Ignition Coil/Driver - Cylinder 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 6849 Ignition Coil/Driver - Cylinder 5 Ignition Coil/Driver - Cylinder 6 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 6850 Ignition Coil/Driver - Cylinder 7 Ignition Coil/Driver - Cylinder 8 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 6851 Ignition Coil: Description and Operation IGNITION COILS Ignition Coils The following are the 2 different manufacturers for the ignition coils. ^ Melco (1), square design ^ Delphi (2), round design These 2 coils use 2 different spark plug wire lengths, and mounting brackets. Each ignition coil has an ignition 1 feed and a ground. The PCM supplies a low reference and an Ignition Control (IC) circuit. Each ignition coil contains a solid state driver module as the primary element. The PCM signals the coil driver to initiate a firing event by applying the IC circuit voltage for the appropriate time, or dwell. When the voltage is removed the coil fires the spark plug. The coils are current limited to prevent overloading if the IC current is held high too long. IGNITION COIL MOUNTING BRACKETS Ignition Coil Mounting Brackets The following are the 2 different types of mounting brackets. ^ Melco (1), square design ^ Delphi (2), round design The ignition coil mounting brackets must match the appropriate coil type. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 6852 Spark Plug Wire Length V8 The following are the 2 different lengths of spark plug wire. ^ Melco (1), square design-Uses a spark plug wire that is 145 mm length cable seal to cable seal. ^ Delphi (2), round design-Uses a spark plug wire that is 110 mm length cable seal to cable seal. The ignition coil wires must match the appropriate coil type. The spark plugs are connected to their respective coils by a short secondary wire. The plugs are tipped with platinum for long wear and higher efficiency. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 6853 Ignition Coil: Service and Repair REMOVAL PROCEDURE 1. Disconnect the spark plug wires at the ignition coils. 2. Disconnect the ignition coil harness connector. 3. Remove the ignition coil mounting bolts. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 6854 4. Remove the ignition coil. INSTALLATION PROCEDURE 1. Install the ignition coil to the bracket. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ignition coil mounting bolts. Tighten Tighten the ignition coil mounting bolts to 8 N.m (71 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 6855 3. Connect the ignition coil harness connector. 4. Connect the spark plug wires at the ignition coils. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations Ignition Relay: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 6859 Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 6860 Ignition Relay: Testing and Inspection CIRCUIT DESCRIPTION The ignition relay supplies battery positive voltage to the following components: ^ The fuel injectors ^ The ignition coils ^ The powertrain control module (PCM) ^ The throttle actuator control (TAC) module DIAGNOSTIC AIDS The following will occur if the ignition relay fails to close: ^ The engine cranks, but does not run. ^ Scan tool data will be available. ^ Instrument panel lights will illuminate. TEST DESCRIPTION Steps 1-5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 6861 Steps 6-11 The numbers below refer to the step numbers on the diagnostic table. 2. This step is testing the battery positive voltage circuit of the ignition relay. 3. This step is testing the ignition 1 positive voltage circuit of the ignition relay. 4. This step is testing the coil ground circuit of the ignition relay. 5. This step isolates the circuits from the ignition relay. All of the circuits at the relay are good if the test lamp illuminates. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set Knock Sensor: Customer Interest Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-023A Date: June, 2002 TECHNICAL Subject: Audible Spark Knock (Detonation), MIL Illuminated, DTC P0332 Set (Replace Rear Bank Knock Sensor and RTV Area Around Sensor) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird with 5.7L Engine (VIN G - RPO LS1) 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalance 1999-2002 GMC Sierra, Yukon, Yukon XL 2002 Cadillac Escalade, Escalade EXT with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, N, U - RPOS LR4, LM7, L59, L09, L04) This bulletin is being revised to add Cadillac Escalade and Cadillac Escalade EXT to the Models. Please discard Corporate Bulletin Number 02-06-04-023 (Section 6 - Engine/Propulsion System). Condition Some customers may comment on a mild to severe engine ping (commonly referred to as spark knock), usually worse during acceleration and/or an illuminated MIL. Upon investigation, the technician may find DTC P0332 set. Cause This condition may be the result of corrosion of the rear bank knock sensor due to water intrusion into the sensor cavity. This condition is more apparent on vehicles in which customers frequently wash the engine compartment. Correction Replace the rear bank knock sensor and build a dam (wall) around the sensor using RTV to divert water away from the sensor. Use the procedure and part number listed. 1. Remove the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. 2. Remove the wiring harness assembly from the knock sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 6870 3. Remove the rear bank knock sensor. 4. Install the new rear bank knock sensor. Tighten Tighten the knock sensor to 20 N.m (15 lb ft). 5. Install the wiring harness assembly to the knock sensor. 6. Apply a bead of RTV silicone sealant approximately 9 mm (3/8 in) wide and 6 mm (1/4 in) high along the outside edge of the ridge on the engine block valley cover around the rear bank knock sensor. DO NOT form a complete circle. Leave the rear section open as shown. 7. From the underside of the intake manifold, completely remove the rear intake manifold seal (foam material). 8. Install the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 6871 For vehicles repaired under warranty, use the table as shown DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set Knock Sensor: All Technical Service Bulletins Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-023A Date: June, 2002 TECHNICAL Subject: Audible Spark Knock (Detonation), MIL Illuminated, DTC P0332 Set (Replace Rear Bank Knock Sensor and RTV Area Around Sensor) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird with 5.7L Engine (VIN G - RPO LS1) 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalance 1999-2002 GMC Sierra, Yukon, Yukon XL 2002 Cadillac Escalade, Escalade EXT with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, N, U - RPOS LR4, LM7, L59, L09, L04) This bulletin is being revised to add Cadillac Escalade and Cadillac Escalade EXT to the Models. Please discard Corporate Bulletin Number 02-06-04-023 (Section 6 - Engine/Propulsion System). Condition Some customers may comment on a mild to severe engine ping (commonly referred to as spark knock), usually worse during acceleration and/or an illuminated MIL. Upon investigation, the technician may find DTC P0332 set. Cause This condition may be the result of corrosion of the rear bank knock sensor due to water intrusion into the sensor cavity. This condition is more apparent on vehicles in which customers frequently wash the engine compartment. Correction Replace the rear bank knock sensor and build a dam (wall) around the sensor using RTV to divert water away from the sensor. Use the procedure and part number listed. 1. Remove the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. 2. Remove the wiring harness assembly from the knock sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 6877 3. Remove the rear bank knock sensor. 4. Install the new rear bank knock sensor. Tighten Tighten the knock sensor to 20 N.m (15 lb ft). 5. Install the wiring harness assembly to the knock sensor. 6. Apply a bead of RTV silicone sealant approximately 9 mm (3/8 in) wide and 6 mm (1/4 in) high along the outside edge of the ridge on the engine block valley cover around the rear bank knock sensor. DO NOT form a complete circle. Leave the rear section open as shown. 7. From the underside of the intake manifold, completely remove the rear intake manifold seal (foam material). 8. Install the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 6878 For vehicles repaired under warranty, use the table as shown DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Page 6879 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6882 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6883 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6884 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6885 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6886 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6887 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6888 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6889 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6890 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6891 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6892 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6893 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6894 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6895 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6896 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6897 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6898 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6899 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6900 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6901 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6902 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6903 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6904 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6905 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6906 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6907 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6908 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6909 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6910 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6911 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6912 Knock Sensor (KS) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 6913 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: ^ The broadband single wire sensor ^ The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: ^ All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. ^ The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near Top Dead Center (TDC) of the firing stroke. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 6914 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Remove the knock sensor wiring harness assembly. 3. Remove the knock sensor (KS). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 6915 1. Install the knock sensor. Tighten Torque the sensor to 20 N.m (15 lb ft). 2. Install the knock sensor wiring harness assembly. 3. Install the intake manifold. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ignition Relay: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 6920 Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 6921 Ignition Relay: Testing and Inspection CIRCUIT DESCRIPTION The ignition relay supplies battery positive voltage to the following components: ^ The fuel injectors ^ The ignition coils ^ The powertrain control module (PCM) ^ The throttle actuator control (TAC) module DIAGNOSTIC AIDS The following will occur if the ignition relay fails to close: ^ The engine cranks, but does not run. ^ Scan tool data will be available. ^ Instrument panel lights will illuminate. TEST DESCRIPTION Steps 1-5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 6922 Steps 6-11 The numbers below refer to the step numbers on the diagnostic table. 2. This step is testing the battery positive voltage circuit of the ignition relay. 3. This step is testing the ignition 1 positive voltage circuit of the ignition relay. 4. This step is testing the coil ground circuit of the ignition relay. 5. This step isolates the circuits from the ignition relay. All of the circuits at the relay are good if the test lamp illuminates. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6929 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6930 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6931 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6932 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6933 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6934 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6935 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6936 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6937 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6938 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6939 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6940 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6941 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6942 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6943 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6944 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6945 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6946 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6947 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6948 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6949 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6950 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6951 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6952 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6953 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6954 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6955 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6956 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6957 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6958 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6959 Camshaft Position (CMP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 6960 Camshaft Position Sensor: Description and Operation The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 6961 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. Camshaft Position Sensor (CMP) 1. Remove the engine sight shield, as necessary. 2. Disconnect the CMP sensor electrical connector. 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor. INSTALLATION PROCEDURE Camshaft Position Sensor (CMP) 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CMP sensor electrical connector. 4. Install the engine sight shield, as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6967 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6968 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6969 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6970 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6971 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6972 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6973 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6974 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6975 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6976 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6977 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6978 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6979 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6980 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6981 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6982 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6983 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6984 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6985 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6986 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6987 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6988 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6989 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6990 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6991 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6992 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6993 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6994 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6995 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6996 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6997 Crankshaft Position (CKP) Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 6998 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at Top Dead Center (TDC). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module (PCM) for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. Observe the fuel cut-off for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: ^ Block the drive wheels. ^ Apply the vehicles parking brake. ^ Cycle the ignition from OFF to ON. ^ Apply and hold the brake pedal. ^ Start and idle the engine. ^ Turn OFF the AC. ^ Place the vehicle's transmission in Park (A/T) or Neutral (M/T). ^ The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. With the scan tool, enable the CKP system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-off is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine Mechanical. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 7001 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure when the crankshaft position sensor is removed or replaced. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the starter. 4. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 7002 5. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 6. Remove the CKP sensor retaining bolt. 7. Remove the CKP sensor. INSTALLATION PROCEDURE Crankshaft Position Sensor (CKP) 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor retaining fastener. Tighten Tighten the bolt to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 7003 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set Knock Sensor: Customer Interest Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-023A Date: June, 2002 TECHNICAL Subject: Audible Spark Knock (Detonation), MIL Illuminated, DTC P0332 Set (Replace Rear Bank Knock Sensor and RTV Area Around Sensor) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird with 5.7L Engine (VIN G - RPO LS1) 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalance 1999-2002 GMC Sierra, Yukon, Yukon XL 2002 Cadillac Escalade, Escalade EXT with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, N, U - RPOS LR4, LM7, L59, L09, L04) This bulletin is being revised to add Cadillac Escalade and Cadillac Escalade EXT to the Models. Please discard Corporate Bulletin Number 02-06-04-023 (Section 6 - Engine/Propulsion System). Condition Some customers may comment on a mild to severe engine ping (commonly referred to as spark knock), usually worse during acceleration and/or an illuminated MIL. Upon investigation, the technician may find DTC P0332 set. Cause This condition may be the result of corrosion of the rear bank knock sensor due to water intrusion into the sensor cavity. This condition is more apparent on vehicles in which customers frequently wash the engine compartment. Correction Replace the rear bank knock sensor and build a dam (wall) around the sensor using RTV to divert water away from the sensor. Use the procedure and part number listed. 1. Remove the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. 2. Remove the wiring harness assembly from the knock sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 7017 3. Remove the rear bank knock sensor. 4. Install the new rear bank knock sensor. Tighten Tighten the knock sensor to 20 N.m (15 lb ft). 5. Install the wiring harness assembly to the knock sensor. 6. Apply a bead of RTV silicone sealant approximately 9 mm (3/8 in) wide and 6 mm (1/4 in) high along the outside edge of the ridge on the engine block valley cover around the rear bank knock sensor. DO NOT form a complete circle. Leave the rear section open as shown. 7. From the underside of the intake manifold, completely remove the rear intake manifold seal (foam material). 8. Install the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Customer Interest for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 7018 For vehicles repaired under warranty, use the table as shown DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set Knock Sensor: All Technical Service Bulletins Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-023A Date: June, 2002 TECHNICAL Subject: Audible Spark Knock (Detonation), MIL Illuminated, DTC P0332 Set (Replace Rear Bank Knock Sensor and RTV Area Around Sensor) Models: 1998-2002 Chevrolet Camaro, Corvette 1998-2002 Pontiac Firebird with 5.7L Engine (VIN G - RPO LS1) 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalance 1999-2002 GMC Sierra, Yukon, Yukon XL 2002 Cadillac Escalade, Escalade EXT with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, N, U - RPOS LR4, LM7, L59, L09, L04) This bulletin is being revised to add Cadillac Escalade and Cadillac Escalade EXT to the Models. Please discard Corporate Bulletin Number 02-06-04-023 (Section 6 - Engine/Propulsion System). Condition Some customers may comment on a mild to severe engine ping (commonly referred to as spark knock), usually worse during acceleration and/or an illuminated MIL. Upon investigation, the technician may find DTC P0332 set. Cause This condition may be the result of corrosion of the rear bank knock sensor due to water intrusion into the sensor cavity. This condition is more apparent on vehicles in which customers frequently wash the engine compartment. Correction Replace the rear bank knock sensor and build a dam (wall) around the sensor using RTV to divert water away from the sensor. Use the procedure and part number listed. 1. Remove the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. 2. Remove the wiring harness assembly from the knock sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 7024 3. Remove the rear bank knock sensor. 4. Install the new rear bank knock sensor. Tighten Tighten the knock sensor to 20 N.m (15 lb ft). 5. Install the wiring harness assembly to the knock sensor. 6. Apply a bead of RTV silicone sealant approximately 9 mm (3/8 in) wide and 6 mm (1/4 in) high along the outside edge of the ridge on the engine block valley cover around the rear bank knock sensor. DO NOT form a complete circle. Leave the rear section open as shown. 7. From the underside of the intake manifold, completely remove the rear intake manifold seal (foam material). 8. Install the intake manifold. Refer to the Intake Manifold Replacement procedure in the Engine Controls sub-section of the appropriate Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Knock Sensor: > 02-06-04-023A > Jun > 02 > Engine Controls - Spark Knock/MIL ON/ DTC P0332 Set > Page 7025 For vehicles repaired under warranty, use the table as shown DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Page 7026 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7029 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7030 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7031 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7032 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7033 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7034 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7035 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7039 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7041 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7042 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7043 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7044 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7045 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7046 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7047 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7048 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7049 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7050 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7051 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7052 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7053 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7054 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7055 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7056 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7057 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7058 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7059 Knock Sensor (KS) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 7060 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: ^ The broadband single wire sensor ^ The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: ^ All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. ^ The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near Top Dead Center (TDC) of the firing stroke. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 7061 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Remove the knock sensor wiring harness assembly. 3. Remove the knock sensor (KS). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 7062 1. Install the knock sensor. Tighten Torque the sensor to 20 N.m (15 lb ft). 2. Install the knock sensor wiring harness assembly. 3. Install the intake manifold. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - New Spark Plugs & Gapping Info. Spark Plug: Technical Service Bulletins Ignition System - New Spark Plugs & Gapping Info. INFORMATION Bulletin No.: 03-06-04-060B Date: July 30 2008 Subject: Information on New Spark Plugs and Gapping Models Attention: Please disregard the Set Gap Per Vehicle Specification statement on the side of an ACOelco(R) Iridium Spark Plug Box. The statement will be removed from the boxes in the future. Supercede: This bulletin is being revised to add the Chevrolet SSR and the 2005 Pontiac GTO. Please discard Corporate Bulletin Number 03-06-04-060A (Section 06 - Engine/Propulsion System). ^ A new spark plug has been released for use in the above vehicles. The new spark plug has an Iridium tip instead of the current Platinum tip. Due to the different tip design the gap of the spark plug has also changed. ^ The new spark plug P/N 12571164 with AC Delco P/N 41-985 is gapped to 1.01 mm (0.040 in) when the spark plug is made. Notice: The spark plug gap is set during manufacturing and should not be changed or damage to the spark plug may result. Any new spark plug found to not be properly gapped should not be used. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 7067 Spark Plug: Specifications This article has been updated with TSB #03-06-04-060B INFORMATION ON NEW SPARK PLUGS AND GAPPING SPARK PLUG GAP.............................................................................................................................. .................................................. 1.01 mm (0.040 in.) ^ A new spark plug has been released for use in the above vehicles. The new spark plug has an Iridium tip instead of the current Platinum tip. Due to the different tip design, the gap of the spark plug has also changed. ^ The new spark plug, P/N 12571164 with AC Delco P/N 41-985, is gapped to 1.01mm (0.040 inches) when the spark plug is made. Notice: The spark plug gap is set during manufacturing and should not be changed or damage to the spark plug may result. Any new spark plug found to not be properly gapped should not be used. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 7068 Spark Plug: Application and ID AC Plug Type ...................................................................................................................................... ................................................................... 25171803 NGK Plug Type .................................................................................................................................... ................................................................. 12567759 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection Spark Plug: Service and Repair Spark Plug Inspection SPARK PLUG USAGE ^ Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. ^ Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION ^ Inspect the terminal P05 (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. ^ Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 7071 ^ Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). ^ Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. ^ A rattling sound indicates internal damage. ^ A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. ^ Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION ^ Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. ^ Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures ^ Leaking fuel injectors ^ Excessive fuel pressure ^ Restricted air filter element ^ Incorrect combustion Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 7072 - Reduced ignition system voltage output ^ Weak coils ^ Worn ignition wires ^ Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. ^ Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 7073 Spark Plug: Service and Repair Spark Plug Replacement REMOVAL PROCEDURE 1. Remove the spark plug wires. 2. Loosen each spark plug 1 or 2 turns. 3. Brush or air blast away any dirt from around the spark plugs. 4. Remove the spark plugs 1 at a time. Place each plug in a tray marked with the corresponding cylinder numbers. INSTALLATION PROCEDURE 1. Properly position each spark plug washer. 2. Inspect each spark plug gap. Adjust each plug as needed. Specification Spark plug gap: 1.52 mm (0.060 in) NOTE: Refer to Fastener Notice in Service Precautions. 3. Hand start the spark plugs in the corresponding cylinders. 4. Tighten the spark plugs. Tighten ^ For used heads tighten the spark plugs to 15 N.m (11 lb ft). ^ For new aluminum heads tighten the spark plugs to 20 N.m (15 lb ft). ^ For new iron heads, tighten the spark plugs to 30 N.m (22 lb ft). 5. Install the spark plug wires. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications Pressure Regulating Solenoid: Specifications 4L60-E Pressure Control Solenoid Bracket to Valve Body Bolt ....................................................................... .......................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) 4L80-E Pressure Control Solenoid Bracket to Valve Body .............................................................................. ...................................................................................................................... 8 Nm (71 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E > Page 7082 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E Pressure Regulating Solenoid: Service and Repair 4L60-E Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7085 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7086 Pressure Regulating Solenoid: Service and Repair 4L80-E Pressure Regulator Replacement ^ Tools Required J 36850 Transjel Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 3. Remove the reverse boost valve bushing retainer ring (2). 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7087 1. Install the pressure regulator valve with J 36850. 2. Pre-assemble the following parts: ^ The reverse boost valve bushing ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission oil pan and the oil filter. 6. Lower the vehicle. 7. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 7091 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the body control module bracket. 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator away from the steering column jacket assembly and the cable shift cam assembly. 6. Remove the automatic transmission shift lock control actuator. Installation Procedure 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket assembly and the cable shift cam assembly. 2. Connect the electrical connector 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 7092 3.1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. 3.2. Press on the adjuster block (2) to compress the internal adjuster spring, which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 4.1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 4.2. Depress the brake pedal to move the shift lever out of the park position. 4.3. The actuator will be energized. 4.4. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the body control module bracket. 6. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications 4L80-E Solenoid to Valve Body ....................................................................................................................... ............................................... 8 Nm (71 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E Shift Solenoid: Diagrams 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E > Page 7098 Shift Solenoid: Diagrams 4L80-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 7099 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 7100 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 7101 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 7102 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications 4L60-E TCC Solenoid Assembly to Case Bolt ..................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E Torque Converter Clutch Solenoid: Diagrams 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E > Page 7108 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E Torque Converter Clutch Solenoid: Service and Repair 4L60-E Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7111 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts, which retain the internal wiring harness. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7112 11. Using J28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7113 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts, which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7114 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7115 Torque Converter Clutch Solenoid: Service and Repair 4L80-E Torque Converter Clutch (TCC) Valve and Spring Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the oil filter. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 3. Remove the valve bore plug retainer ring (1). 4. Remove the following parts: ^ The valve bore plug ^ The TCC valve ^ The TCC valve spring Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7116 1. Install the following parts: ^ The TCC valve spring ^ The TCC valve ^ The valve bore plug 2. Install the valve bore plug retainer ring (1). 3. Install the transmission oil pan and oil filter. 4. Lower the vehicle. 5. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications NVG 149-NP (One Speed Automatic) Transfer Case Motor/Encoder Bolts ..................................................................................................................................................... 20 Nm (14 ft. lbs.) NVG 236/246-NP8 (Two Speed Automatic) Transfer Case Motor/Encoder Bolts ..................................................................................................................................................... 20 Nm (15 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Front Axle Actuator Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Front Axle Actuator > Page 7123 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Front Axle Actuator > Page 7124 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 7125 Transfer Case Actuator: Service and Repair Transfer Case Motor/Encoder Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield. 3. Remove the front propeller shaft. 4. Remove the motor/encoder electrical connectors. 5. Remove the motor/encoder mounting bolts. 6. Remove the motor/encoder assembly. 7. Remove the motor/encoder gasket. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 7126 Important: ^ If the motor/encoder assembly is being replaced because it is defective, make sure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench if necessary. ^ When installing the motor/encoder unit to the transfer case, make sure that the transfer case is indexed properly and it is flat against the transfer case before tightening the mounting bolts. 1. Install the NEW motor/encoder gasket to the transfer case. 2. Install the motor/encoder to the transfer case. Notice: Refer to Fastener Notice in Service Precautions. 3. Install motor/encoder mounting bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 4. Install the motor/encoder electrical connector. Ensure that the retention clips activate. 5. Install the front propeller shaft. 6. Install the transfer case shield. 7. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation The IPC displays the vehicle speed based on the vehicle speed signal from the PCM. The PCM converts the data from the vehicle speed sensor to a 4000 pulses/mile signal. The IPC uses the vehicle speed signal circuit from the PCM in order to calculate the vehicle speed. The speedometer defaults to 0 km/h (0 mph) if a malfunction in the vehicle speed signal circuit exists. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Service and Repair Malfunction Indicator Lamp - Transfer Case: Service and Repair Service AWD/4WD Indicator Lamp Illumination of the Lamp indicates a problem with the drive system. There will probably be a Transfer Case Code set to aid in diagnostics. The only way to get the light to go off is to clear Transfer Case codes. This light can NOT be shut off or reset any other way. Transfer Case codes should be read and repaired before clearing them. Refer to Transfer Case. See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 7142 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 Control Module: Diagrams Transfer Case Shift Control Module - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 > Page 7145 Transfer Case Shift Control Module - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 > Page 7146 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 7147 Control Module: Service and Repair Transfer Case Shift Control Module Replacement Removal Procedure 1. Remove the IP trim bezel. 2. Pull out the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly in order to disconnect the electrical connectors. 3. Disconnect all the electrical connectors from the lamp switch, cargo lamp and 4WD shift buttons assembly. 4. Remove the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly from the vehicle. 5. Remove the electrical harness retainer from the IP support beam. 6. Disconnect the 2 electrical connectors from the transfer case shift control module. 7. Move the electrical harness to the left side in order to make room to turn the transfer case shift control module. 8. Rotate the transfer case shift control module about 45 degrees counter clockwise while pulling out at the same time until the module is Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 7148 approximately 90 degrees from the original position. 9. Pull out the module from the vehicle. Installation Procedure 1. Move the electrical harness to the left side in order to make room to install the transfer case shift control module. 2. Install the transfer case shift control module so that the electrical connector ports are to the right or pointing towards the instrument cluster. 3. While installing the transfer case shift control module rotate clockwise until the module is in place and the electrical connector ports are facing outwards. 4. Install the electrical harness retainer to the IP support beam. 5. Connect the 2 electrical connectors to the transfer case shift control module. 6. Install the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly the vehicle. 7. Connect all the electrical connectors to the lamp switch, cargo lamp and 4WD shift buttons assembly. 8. Install the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly in place. 9. Install the IP trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 7149 10. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications 4L60-E Transmission Fluid Pressure Manual Valve Position Switch to Valve ................................................. ................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E A/T Fluid Pressure Manual Valve Position Switch Connector, Wiring Harness Side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E > Page 7157 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 7158 Fluid Pressure Sensor/Switch: Service and Repair For information relating to service of this component please refer to Valve Body; Service And Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Transmission Mode Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7163 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7164 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for voltage through the body wiring harness junction block. 7. This step tests for ground integrity at the splice pack. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7165 Transmission Mode Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7166 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7167 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for voltage through the body wiring harness junction block. 7. This step tests for ground integrity at the splice pack. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 4L60-E Park/Neutral Position Switch Screw .................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E > Page 7173 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E Transmission Position Switch/Sensor: Adjustments 4L60-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E > Page 7176 Transmission Position Switch/Sensor: Adjustments 4L80-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E Transmission Position Switch/Sensor: Service and Repair 4L60-E Park Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 7179 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 7180 Transmission Position Switch/Sensor: Service and Repair 4L80-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 7181 4. Position the tool J41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications 4L60-E Speed Sensor Retainer Bolt ................................................................................................................................................. 10.5-13.5 Nm (7.7-10 ft. lbs.) 4L80-E Speed Sensor and Bracket Assembly to Case .................................................................................................................................... 11 Nm (97 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E Vehicle Speed Sensor (VSS) Sensor Connector, Wiring Harness Side (4L60-E) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E > Page 7187 Transmission Speed Sensor: Diagrams 4L80-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E Transmission Speed Sensor: Service and Repair 4L60-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 7190 Transmission Speed Sensor: Service and Repair 4L80-E Vehicle Speed Sensor (VSS) Replacement- Input Vehicle Speed Sensor (VSS) Replacement- Input Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor (1) electrical connector. 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1) and the bracket assembly from the case. 5. Inspect the vehicle speed sensor assembly (1) for any evidence of damage. Installation Procedure. 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1) and the bracket assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector. 5. Lower the vehicle. Vehicle Speed Sensor (VSS) Replacement-Output Vehicle Speed Sensor (VSS) Replacement-Output Removal Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 7191 1. Raise the vehicle. Refer to Vehicle Lifting. Important: This procedure is for 2WD vehicles. If the vehicle is equipped with 4WD, the output speed sensor is located on the transfer case. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2) and the bracket assembly from the case. 5. Inspect the output speed sensor assembly (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2) and the bracket assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the output speed sensor electrical connector. 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Transmission Fluid Temperature (TFT) Sensor Connector, Wiring Harness Side (4L80-E) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 02-04-21-004 > Apr > 02 > Transfer Case Switch - `Service 4WD' Indicator ON Four Wheel Drive Selector Switch: Customer Interest Transfer Case Switch - `Service 4WD' Indicator ON File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-004 Date: April, 2002 TECHNICAL Subject: " "Service 4WD" Indicator Illuminated, DTC B2725 Set (Replace Transfer Case Shift Control Switch) Models: 1999-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Avalanche, Suburban, Tahoe, Yukon, Yukon XL) with Four Wheel Drive and NVG 236/246 Transfer Case (RPO NP8) Condition Some customers may comment on the Service 4WD indicator illuminating. Upon investigation, the technician may find DTC B2725 set. Cause The condition may be due to a intermittent fault in the transfer case shift control switch. Correction Important: The transfer case shift control module should not need replacement. DO NOT replace P/N 15749703 unless diagnosis points to the module as the malfunction. Replace the transfer case shift control switch using published Service Information procedures. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 02-04-21-004 > Apr > 02 > Transfer Case Switch - `Service 4WD' Indicator ON Four Wheel Drive Selector Switch: All Technical Service Bulletins Transfer Case Switch - `Service 4WD' Indicator ON File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-004 Date: April, 2002 TECHNICAL Subject: " "Service 4WD" Indicator Illuminated, DTC B2725 Set (Replace Transfer Case Shift Control Switch) Models: 1999-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Avalanche, Suburban, Tahoe, Yukon, Yukon XL) with Four Wheel Drive and NVG 236/246 Transfer Case (RPO NP8) Condition Some customers may comment on the Service 4WD indicator illuminating. Upon investigation, the technician may find DTC B2725 set. Cause The condition may be due to a intermittent fault in the transfer case shift control switch. Correction Important: The transfer case shift control module should not need replacement. DO NOT replace P/N 15749703 unless diagnosis points to the module as the malfunction. Replace the transfer case shift control switch using published Service Information procedures. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Transfer Case Shift Control Switch - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Transfer Case Shift Control Switch - C1 > Page 7211 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 7212 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel bezel trim piece. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. 1. Install the transfer case driver control switch into the instrument panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 7213 2. Install the instrument panel trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Page 7218 Speed Sensor: Specifications Transfer Case Speed Sensors ............................................................................................................ ........................................................ 15 Nm (11 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 7221 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) Speed Sensor: Service and Repair NVG 149-NP (One Speed Automatic) Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the electrical connector from the speed sensor. 3. Remove the speed sensor from the transfer case. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 7224 1. Install the right rear speed sensor into the transfer case. ^ Tighten the right rear speed sensor to 31 Nm (23 ft. lbs.). 2. Install the electrical connector to the speed sensor. 3. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 7225 Speed Sensor: Service and Repair NVG 236/246-NP8 (Two Speed Automatic) Transfer Case Speed Sensor Replacement (Front) Transfer Case Speed Sensor Replacement (Front) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield. 3. Remove the transfer case front speed sensor electrical connector. 4. Remove the transfer case front speed sensor. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 7226 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case front speed sensor into the transfer case. ^ Tighten the transfer case front speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case front speed sensor electrical connector. 3. Install the transfer case shield. 4. Lower the vehicle. Refer to Vehicle Lifting. Transfer Case Speed Sensor Replacement (Right Rear) Transfer Case Speed Sensor Replacement (Right Rear) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 7227 2. Remove the transfer case right rear electrical connector. 3. Remove the transfer case right rear speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case right rear speed sensor to the transfer case. ^ Tighten the transfer case right rear speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case right rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Transfer Case Speed Sensor Replacement (Left Rear) Transfer Case Speed Sensor Replacement (Left Rear) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case left rear speed sensor electrical connector. 3. Remove the transfer case left rear speed sensor. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 7228 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case left rear speed sensor into the transfer case. ^ Tighten the transfer case left rear speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case left rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 04-06-04-040 > Jun > 04 > Fuel System - Low/Rough or Unstable Idle PROM - Programmable Read Only Memory: Customer Interest Fuel System - Low/Rough or Unstable Idle Bulletin No.: 04-06-04-040 Date: June 14, 2004 TECHNICAL Subject: Idle Instability, Low or Rough Idle with Electronic Throttle Control (Clean Throttle Body) Models: 2002-2003 Cadillac Escalade, Escalade EXT 2000-2003 Chevrolet Silverado, Suburban, Tahoe 2002-2003 Chevrolet Avalanche 2000-2003 GMC Sierra, Yukon, Yukon XL with 4.8L, 5.3L or 6.0L V8 Engine (VINs V, T, Z, N, U - RPOs LR4, LM7, L59, LQ9, LQ4) and Electronic Throttle Control Condition Some owners may comment on an idle instability, low idle speed or rough idle. Cause Condition may be caused by deposits in the throttle body bore. Correction Clean throttle body bore and throttle valve plate of carbon using a shop rag and an appropriate cleaner. Refer to Engine Controls Repair Procedures - Throttle Body Cleaning Procedure. This procedure may be performed at any mileage necessary. Check to determine if the PCM calibration has been previously updated to one that includes the update for throttle body coking. For 2003 model year vehicles, look in the operating system portion of the calibration. For 2000-2002 model year vehicles, look in the engine portion of the calibration. If not, then update the PCM calibration to the latest calibration. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-06-04-040 > Jun > 04 > Fuel System - Low/Rough or Unstable Idle PROM - Programmable Read Only Memory: All Technical Service Bulletins Fuel System Low/Rough or Unstable Idle Bulletin No.: 04-06-04-040 Date: June 14, 2004 TECHNICAL Subject: Idle Instability, Low or Rough Idle with Electronic Throttle Control (Clean Throttle Body) Models: 2002-2003 Cadillac Escalade, Escalade EXT 2000-2003 Chevrolet Silverado, Suburban, Tahoe 2002-2003 Chevrolet Avalanche 2000-2003 GMC Sierra, Yukon, Yukon XL with 4.8L, 5.3L or 6.0L V8 Engine (VINs V, T, Z, N, U - RPOs LR4, LM7, L59, LQ9, LQ4) and Electronic Throttle Control Condition Some owners may comment on an idle instability, low idle speed or rough idle. Cause Condition may be caused by deposits in the throttle body bore. Correction Clean throttle body bore and throttle valve plate of carbon using a shop rag and an appropriate cleaner. Refer to Engine Controls Repair Procedures - Throttle Body Cleaning Procedure. This procedure may be performed at any mileage necessary. Check to determine if the PCM calibration has been previously updated to one that includes the update for throttle body coking. For 2003 model year vehicles, look in the operating system portion of the calibration. For 2000-2002 model year vehicles, look in the engine portion of the calibration. If not, then update the PCM calibration to the latest calibration. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 99-06-03-010A > Jun > 01 > PCM/BCM Replacement - DTC's B001/B1271/B1780 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM/BCM Replacement - DTC's B001/B1271/B1780 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-03-010A Date: June, 2001 INFORMATION Subject: DTCs B1001, B1271 or B1780 Set When Replacing/Reprogramming Other Modules Models: 1999-2002 All Passenger Cars and Trucks With Class 2 Serial Data Communication Between Modules This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 99-06-03-010 (Section 06 - Engine/propulsion System). Class 2 Serial Data Communication allows control modules (i.e. the Powertrain Control Module (PCM), the Body Control Module (BCM), the Dash Integration Module (DIM), the Instrument Panel Cluster (IPC), the radio, the Heating, Ventilation and Air Conditioning (HVAC) Controller, and the Sensing and Diagnostic Module (SDM) to exchange information. This information may be operational information or identification information. Among the identification information exchanged and compared within these modules is the Vehicle Identification Number (VIN). Typically, the PCM broadcasts a portion of the VIN, while another module broadcasts another portion of the VIN. This information is compared by the SDM in order to ensure installation is in the correct vehicle. When the broadcast VIN does not match the VIN stored within the SDM, the following actions occur: ^ DTC B1001 Option Configuration Error is set and deployment of the airbags is inhibited. ^ The VIN information is also used by the radio in order to prevent theft. When the broadcast VIN does not match the VIN stored within the radio, a DTC B1271 ora DTC B1780 Theft Locked is set and the radio is inoperative. This situation may occur when a vehicle is being repaired. When a PCM or a body control type module is replaced, the VIN information must be programmed into the replaced (new) control module. A module which has had VIN information entered into it (for example, one taken from another vehicle) cannot be reprogrammed. VIN information can only be entered into new modules. The ignition must be ON in order to program the control module. Since the VIN information is broadcast when the ignition goes to ON from any other ignition switch position, DTCs may be set in the SDM and/or the radio. Therefore, always follow the specified control module replacement procedures. 1. After completing the repair, turn OFF the ignition for at least 30 seconds. 2. Turn ON the ignition and check for DTCs using a scan tool. If DTCs B1001, B1271, or B178C are present with a history status, DO NOT REPLACE THE SDM OR THE RADIO. 3. Clear the DTCs from all modules using the scan tool. The SDM and/or the radio should then operate properly. 4. Ensure the proper operation of the SDM by turning OFF the ignition and then turning ON the ignition. The air bag warning indicator should flash seven times and then go OFF. Refer to Corporate Bulletin Number 99-09-41-001 for additional information regarding proper reprogramming of the new/replaced module. Clearing codes from the other modules is part of the replacement and reprogramming procedure for the replaced module. The repair is not complete unless all codes have been cleared from all modules. DO NOT SUBMIT CLAIMS FOR OTHER MODULE REPLACEMENTS OR REPROGRAMMING. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 99-06-03-010A > Jun > 01 > PCM/BCM Replacement - DTC's B001/B1271/B1780 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM/BCM Replacement - DTC's B001/B1271/B1780 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-03-010A Date: June, 2001 INFORMATION Subject: DTCs B1001, B1271 or B1780 Set When Replacing/Reprogramming Other Modules Models: 1999-2002 All Passenger Cars and Trucks With Class 2 Serial Data Communication Between Modules This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 99-06-03-010 (Section 06 - Engine/propulsion System). Class 2 Serial Data Communication allows control modules (i.e. the Powertrain Control Module (PCM), the Body Control Module (BCM), the Dash Integration Module (DIM), the Instrument Panel Cluster (IPC), the radio, the Heating, Ventilation and Air Conditioning (HVAC) Controller, and the Sensing and Diagnostic Module (SDM) to exchange information. This information may be operational information or identification information. Among the identification information exchanged and compared within these modules is the Vehicle Identification Number (VIN). Typically, the PCM broadcasts a portion of the VIN, while another module broadcasts another portion of the VIN. This information is compared by the SDM in order to ensure installation is in the correct vehicle. When the broadcast VIN does not match the VIN stored within the SDM, the following actions occur: ^ DTC B1001 Option Configuration Error is set and deployment of the airbags is inhibited. ^ The VIN information is also used by the radio in order to prevent theft. When the broadcast VIN does not match the VIN stored within the radio, a DTC B1271 ora DTC B1780 Theft Locked is set and the radio is inoperative. This situation may occur when a vehicle is being repaired. When a PCM or a body control type module is replaced, the VIN information must be programmed into the replaced (new) control module. A module which has had VIN information entered into it (for example, one taken from another vehicle) cannot be reprogrammed. VIN information can only be entered into new modules. The ignition must be ON in order to program the control module. Since the VIN information is broadcast when the ignition goes to ON from any other ignition switch position, DTCs may be set in the SDM and/or the radio. Therefore, always follow the specified control module replacement procedures. 1. After completing the repair, turn OFF the ignition for at least 30 seconds. 2. Turn ON the ignition and check for DTCs using a scan tool. If DTCs B1001, B1271, or B178C are present with a history status, DO NOT REPLACE THE SDM OR THE RADIO. 3. Clear the DTCs from all modules using the scan tool. The SDM and/or the radio should then operate properly. 4. Ensure the proper operation of the SDM by turning OFF the ignition and then turning ON the ignition. The air bag warning indicator should flash seven times and then go OFF. Refer to Corporate Bulletin Number 99-09-41-001 for additional information regarding proper reprogramming of the new/replaced module. Clearing codes from the other modules is part of the replacement and reprogramming procedure for the replaced module. The repair is not complete unless all codes have been cleared from all modules. DO NOT SUBMIT CLAIMS FOR OTHER MODULE REPLACEMENTS OR REPROGRAMMING. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications Pressure Regulating Solenoid: Specifications 4L60-E Pressure Control Solenoid Bracket to Valve Body Bolt ....................................................................... .......................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) 4L80-E Pressure Control Solenoid Bracket to Valve Body .............................................................................. ...................................................................................................................... 8 Nm (71 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E > Page 7259 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E Pressure Regulating Solenoid: Service and Repair 4L60-E Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7262 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7263 Pressure Regulating Solenoid: Service and Repair 4L80-E Pressure Regulator Replacement ^ Tools Required J 36850 Transjel Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 3. Remove the reverse boost valve bushing retainer ring (2). 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7264 1. Install the pressure regulator valve with J 36850. 2. Pre-assemble the following parts: ^ The reverse boost valve bushing ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission oil pan and the oil filter. 6. Lower the vehicle. 7. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 7268 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the body control module bracket. 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator away from the steering column jacket assembly and the cable shift cam assembly. 6. Remove the automatic transmission shift lock control actuator. Installation Procedure 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket assembly and the cable shift cam assembly. 2. Connect the electrical connector 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 7269 3.1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. 3.2. Press on the adjuster block (2) to compress the internal adjuster spring, which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 4.1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 4.2. Depress the brake pedal to move the shift lever out of the park position. 4.3. The actuator will be energized. 4.4. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the body control module bracket. 6. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications 4L80-E Solenoid to Valve Body ....................................................................................................................... ............................................... 8 Nm (71 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E Shift Solenoid: Diagrams 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E > Page 7275 Shift Solenoid: Diagrams 4L80-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 7276 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 7277 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 7278 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 7279 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications 4L60-E TCC Solenoid Assembly to Case Bolt ..................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E Torque Converter Clutch Solenoid: Diagrams 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E > Page 7285 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E Torque Converter Clutch Solenoid: Service and Repair 4L60-E Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7288 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts, which retain the internal wiring harness. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7289 11. Using J28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7290 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts, which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7291 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7292 Torque Converter Clutch Solenoid: Service and Repair 4L80-E Torque Converter Clutch (TCC) Valve and Spring Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the oil filter. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 3. Remove the valve bore plug retainer ring (1). 4. Remove the following parts: ^ The valve bore plug ^ The TCC valve ^ The TCC valve spring Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7293 1. Install the following parts: ^ The TCC valve spring ^ The TCC valve ^ The valve bore plug 2. Install the valve bore plug retainer ring (1). 3. Install the transmission oil pan and oil filter. 4. Lower the vehicle. 5. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications NVG 149-NP (One Speed Automatic) Transfer Case Motor/Encoder Bolts ..................................................................................................................................................... 20 Nm (14 ft. lbs.) NVG 236/246-NP8 (Two Speed Automatic) Transfer Case Motor/Encoder Bolts ..................................................................................................................................................... 20 Nm (15 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Front Axle Actuator Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Front Axle Actuator > Page 7300 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Front Axle Actuator > Page 7301 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 7302 Transfer Case Actuator: Service and Repair Transfer Case Motor/Encoder Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield. 3. Remove the front propeller shaft. 4. Remove the motor/encoder electrical connectors. 5. Remove the motor/encoder mounting bolts. 6. Remove the motor/encoder assembly. 7. Remove the motor/encoder gasket. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 7303 Important: ^ If the motor/encoder assembly is being replaced because it is defective, make sure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench if necessary. ^ When installing the motor/encoder unit to the transfer case, make sure that the transfer case is indexed properly and it is flat against the transfer case before tightening the mounting bolts. 1. Install the NEW motor/encoder gasket to the transfer case. 2. Install the motor/encoder to the transfer case. Notice: Refer to Fastener Notice in Service Precautions. 3. Install motor/encoder mounting bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 4. Install the motor/encoder electrical connector. Ensure that the retention clips activate. 5. Install the front propeller shaft. 6. Install the transfer case shield. 7. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications Pressure Regulating Solenoid: Specifications 4L60-E Pressure Control Solenoid Bracket to Valve Body Bolt ....................................................................... .......................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) 4L80-E Pressure Control Solenoid Bracket to Valve Body .............................................................................. ...................................................................................................................... 8 Nm (71 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E > Page 7311 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E Pressure Regulating Solenoid: Service and Repair 4L60-E Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7314 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7315 Pressure Regulating Solenoid: Service and Repair 4L80-E Pressure Regulator Replacement ^ Tools Required J 36850 Transjel Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 3. Remove the reverse boost valve bushing retainer ring (2). 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7316 1. Install the pressure regulator valve with J 36850. 2. Pre-assemble the following parts: ^ The reverse boost valve bushing ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission oil pan and the oil filter. 6. Lower the vehicle. 7. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 7320 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the body control module bracket. 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator away from the steering column jacket assembly and the cable shift cam assembly. 6. Remove the automatic transmission shift lock control actuator. Installation Procedure 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket assembly and the cable shift cam assembly. 2. Connect the electrical connector 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 7321 3.1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. 3.2. Press on the adjuster block (2) to compress the internal adjuster spring, which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 4.1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 4.2. Depress the brake pedal to move the shift lever out of the park position. 4.3. The actuator will be energized. 4.4. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the body control module bracket. 6. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications 4L80-E Solenoid to Valve Body ....................................................................................................................... ............................................... 8 Nm (71 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E Shift Solenoid: Diagrams 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E > Page 7327 Shift Solenoid: Diagrams 4L80-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 7328 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 7329 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 7330 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 7331 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications 4L60-E TCC Solenoid Assembly to Case Bolt ..................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E Torque Converter Clutch Solenoid: Diagrams 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E > Page 7337 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E Torque Converter Clutch Solenoid: Service and Repair 4L60-E Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7340 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts, which retain the internal wiring harness. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7341 11. Using J28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7342 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts, which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7343 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7344 Torque Converter Clutch Solenoid: Service and Repair 4L80-E Torque Converter Clutch (TCC) Valve and Spring Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the oil filter. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 3. Remove the valve bore plug retainer ring (1). 4. Remove the following parts: ^ The valve bore plug ^ The TCC valve ^ The TCC valve spring Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7345 1. Install the following parts: ^ The TCC valve spring ^ The TCC valve ^ The valve bore plug 2. Install the valve bore plug retainer ring (1). 3. Install the transmission oil pan and oil filter. 4. Lower the vehicle. 5. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: Customer Interest A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 7354 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 7360 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Page 7361 Band Apply Servo: Specifications 4L80-E Rear Servo Cover to Case .................................................................................................................. ................................................... 24 Nm (18 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E Band Apply Servo: Service and Repair 4L60-E 2-4 Servo ^ Tools Required J 29714-A Servo Cover Depressor Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the exhaust pipe assembly. 3. Remove the heat shield. 4. Install the J29714-A. 5. Tighten the bolt in order to compress the servo cover. 6. Remove the servo cover retaining ring. 7. Remove the J 29714-A. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E > Page 7364 8. Remove the servo cover and the O-ring seal. If the cover is hung up on the seal, use a pick (2) to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover. 9. Remove the 2-4 servo from the transmission. 10. Inspect the 4th apply piston, 2-4 servo converter, 2nd apply piston, and the servo piston inner housing for the following defects. ^ Cracks ^ Scoring ^ Burrs and nicks Installation Procedure 1. Install new seals on the servo pistons and the servo cover. 2. Install the 2-4 servo assembly into the transmission. 3. Install the J29714-A. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E > Page 7365 4. Tighten the bolt in order to compress the servo cover. 5. Install the servo cover retaining ring. 6. Remove the J29714-A from the oil pan flange. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the oil pan bolt. ^ Tighten the oil pan bolt to 11 Nm (97 inch lbs.). 8. Install the heat shield. 9. Install the two bolts securing the transmission heat shield to the transmission. ^ Tighten the bolts to 17 Nm (13 ft. lbs.). 10. Install the exhaust pipe assembly. 11. Lower the vehicle. 12. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E > Page 7366 Band Apply Servo: Service and Repair 4L80-E Reverse Servo Replacement Reverse Servo Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. 3. Remove the rear servo assembly from the transmission case as follows: ^ Cover bolts (6) ^ Cover (5) ^ Cover gasket (4) ^ Bottom retaining clip (3) ^ Servo piston (2) ^ Outer ring oil seal (1) ^ Inner ring oil seal (7) ^ Accumulator piston (8) ^ Piston seal (9) ^ Washer (10) ^ Servo spring (11) ^ Servo spring retainer (12) ^ Selective pin (13) ^ Accumulator spring (14) Installation Procedure 1. Install the rear servo assembly to the transmission case as follows: ^ Accumulator spring (14) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E > Page 7367 ^ Selective pin (13) ^ Servo spring retainer (12) ^ Servo spring (11) ^ Washer (10) ^ Piston seal (9) ^ Accumulator piston (8) ^ Inner ring oil seal (7) ^ Outer ring oil seal (1) ^ Servo piston (2) ^ Bottom retaining clip (3) ^ Cover gasket (4) ^ Cover (5) ^ Cover Bolt (6) Notice: Refer to Fastener Notice in Service Precautions. 2. Install the cover bolts (61). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 3. Install the transmission oil pan and filter. 4. Lower the vehicle. 5. Fill the transmission to the proper level with DEXRON III transmission fluid. Forward Servo Replacement Forward Servo Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the oil pan and filter. 3. Remove the six forward servo cover bolts, cover, and gasket. 4. Remove the following parts: 4.1. Forward servo piston pin (5) 4.2. O-ring seal (4) 4.3. Servo piston (3) 4.4. Retainer (2) 4.5. Piston spring (1) Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4L60-E > Page 7368 1. Install the following parts: ^ Piston spring (1) ^ Retainer (2) ^ Servo piston (3) ^ O-ring seal (4) ^ Forward servo piston pin (5) Notice: Refer to Fastener Notice in Service Precautions. 2. Install the forward servo gasket, cover, and bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 3. Install the oil pan and filter. 4. Lower the vehicle. 5. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Bell Housing, A/T > Component Information > Specifications Bell Housing: Specifications 4L60-E Converter Housing to Case Screw ........................................................................................................................................ 65.0-75.0 Nm (48-55 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis Case: Technical Service Bulletins A/T - Cracked Case Diagnosis Bulletin No.: 02-07-30-024B Date: August 18, 2005 INFORMATION Subject: Diagnosis of Cracked or Broken Transmission Case Models: 2006 and Prior Cars and Light Duty Trucks 2006 and Prior HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60/4L60-E/4L65-E or 4L80-E/4L85-E or Allison(R) Series 1000 Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 02-07-30-024A (Section 07 - Transmission/Transaxle). Diagnosing the cause of a cracked or broken transmission case requires additional diagnosis and repair or a repeat failure will occur. A cracked or broken transmission case is most often the result of abnormal external torsional forces acting on the transmission case. If none of the conditions listed below are apparent, an internal transmission component inspection may be required. Repairs of this type may be the result of external damage or abuse for which General Motors is not responsible. They are not the result of defects in materials or workmanship. If in doubt, contact your General Motors Service Representative. The following items should be considered: ^ It is important to inspect the vehicle for signs of an out of line condition, impact damage or foreign material to the following components: - The transmission - The engine mounts - The transmission rear mount and crossmember - Vehicle frame damage that alters the front to rear alignment of the driveshaft - The driveshafts (both front and rear) - The wheels (caked with mud, concrete, etc.) - The tires (roundness, lack of cupping, excessive balance weights) - The transfer case (if the vehicle is 4WD) ^ A worn or damaged driveshaft U-Joint has shown to be a frequent cause of transmission case cracking, especially on vehicles that see extended periods of highway driving. Always inspect the U-joint condition when diagnosing this condition. ^ For driveshaft damage or imbalance, Inspect the driveshafts (both front and rear) for dents, straightness/runout or signs of missing balance weights. Also, inspect for foreign material such as undercoat sprayed on the driveshaft. ^ The driveshaft working angles may be excessive or non-canceling, especially if the vehicle carrying height has been altered (lifted or lowered) or if the frame has been extended or modified. ^ Damaged or worn upper or lower rear control arms or bushings. ^ A rear axle that is not seated in the rear spring properly (leaf spring vehicles). ^ Broken rear springs and or worn leaf spring bushings. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 7376 In some cases, the customer may not comment about a vibration but it is important to test drive the vehicle while using the electronic vibration analysis tool in an attempt to locate the cause of the torsional vibration. Refer to the Vibration Diagnosis and Correction sub-section of the appropriate Service Manual for more details on diagnosing and correcting vibrations. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 7377 Case: Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 7378 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 7379 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 7380 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 7381 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 7382 Case: Specifications 4L60-E Case Extension to Case Bolt ................................................................................................................................................ 42.0-48.0 Nm (31-35 ft. lbs.) Case Extension to Case Bolt (4WD Shipping) ...................................... ......................................................................................................................... 11.2-22.6 Nm (8.3-16.7 ft. lbs.) 4L80-E Case Center Support ........................................................................................................................... .................................................. 43 Nm (32 ft. lbs.) Transmission Case to Engine ............................. ................................................................................................................................... 44 Nm (32 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > Heat Shield Replacement - 4L80-E Case: Service and Repair Heat Shield Replacement - 4L80-E Heat Shield Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the two bolts securing the transmission heat shield to the cross member. 3. Remove the transmission heat shield from the cross member. Installation Procedure 1. Install the transmission heat shield to the cross member. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the two bolts securing the transmission heat shield to the cross member. ^ Tighten the bolts to 17 Nm (13 ft. lbs.). 3. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > Heat Shield Replacement - 4L80-E > Page 7385 Case: Service and Repair Vent Hose - 4L80-E Vent Hose Removal Procedure 1. Remove the vent hose clip. 2. Remove the vent hose from the transmission vent. Installation Procedure 1. Install the vent hose to the transmission. 2. Install the vent hose to the clip. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt and the clamp. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 7394 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 7404 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Page 7410 Channel Plate: Specifications 4L60-E Plate to Case Bolt (Shipping) ............................................................................................................................................... 27.0-34.0 Nm (20-25 ft. lbs.) Plate to Converter Bolt (Shipping) ....................................................................................................................................... 27.0-34.0 Nm (20-25 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: Customer Interest A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 7419 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 7420 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-009B > May > 08 > A/T 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 7430 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 7431 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Page 7436 Clutch: Specifications 4L80-E Fourth Clutch Housing ......................................................................................................................... ................................................. 23 Nm (17 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Specifications Automatic Transmission Dipstick - Dipstick Tube: Specifications 4L60-E Oil Level Indicator Bolt ......................................................................................................................... ............................................... 47 Nm (35 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair > 4L60-E Automatic Transmission Dipstick - Dipstick Tube: Service and Repair 4L60-E Filler Tube and Seal Replacement Removal Procedure 1. Remove the transmission oil level indicator. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the nut securing the oil lever indicator tube to the transmission housing. 4. Place a drain pan under the vehicle. 5. Remove the oil level indicator tube from the transmission case and seal. 6. Remove the seal from the transmission case. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair > 4L60-E > Page 7442 1. Install a new seal into the transmission case. 2. Install the oil level indicator tube into the seal. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the nut securing the oil level indicator tube to the transmission stud. ^ Tighten the nut to 18 Nm (13 ft. lbs.). 4. Fill the transmission to the proper level with DEXRON III III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair > 4L60-E > Page 7443 Automatic Transmission Dipstick - Dipstick Tube: Service and Repair 4L80-E Filler Tube and Seal Replacement Removal Procedure 1. Remove the oil level indicator from the oil level indicator tube. 2. For the gasoline engine, remove the stud securing the transmission fluid fill tube bracket to the transmission. 3. For the diesel engine, remove the transmission fluid fill tube bracket and ground wire to the transmission. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove any dirt from the transmission where the fluid fill tube enters the transmission case. 6. Place a drain pan under the transmission. 7. Remove the transmission fluid fill tube from the transmission. Pull the tube upward from the transmission. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair > 4L60-E > Page 7444 8. Remove the transmission fill tube seal. Installation Procedure 1. Install a new oil level indicator tube seal into the transmission case. 2. Install the oil level indicator tube into the seal. Notice: Refer to Fastener Notice in Service Precautions. 3. For the gasoline engine, install the stud securing the oil level indicator tube bracket to the transmission. ^ Tighten the stud to 47 Nm (35 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair > 4L60-E > Page 7445 4. For the diesel engine, install the bolt and nut that secures the oil level indicator tube bracket and ground wire to the transmission. ^ Tighten the bolt and the nut to 25 Nm (18 ft. lbs.). 5. Lower the vehicle. 6. Install the oil level indicator. 7. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Drain Plug, A/T > Component Information > Specifications Drain Plug: Specifications 4L60-E Plug Assembly, Automatic Transmission Oil Pan (C/K) ...................................................................... .............................................................................................................. 30-40 Nm (22.1-29.5 ft. lbs.) 4L80-E Oil Pan Drain Plug ............................................................................................................................... ................................................. 34 Nm (25 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications 4L80-E Extension Housing to Case ................................................................................................................. .................................................. 34 Nm (25 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > 4L60-E Extension Housing: Service and Repair 4L60-E Transmission Extension Housing Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. 5. Remove the transmission mount. 6. Remove the case extension bolts (1). 7. Remove the case extension (2). 8. Remove and discard the case extension O ring seal (3). Installation Procedure 1. Install a new case extension O ring seal (3). 2. Install the case extension (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the case extension bolts (1). ^ Tighten the case extension bolts (1) to 45 Nm (33 ft. lbs.). 4. Install the transmission mount. 5. Install the propeller shaft. 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > 4L60-E > Page 7454 Extension Housing: Service and Repair 4L80-E Transmission Extension Housing Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. 5. Remove the transmission support and the transmission mount. 6. Remove the case extension bolts (3). 7. Remove the case extension (1). 8. Remove and discard the case extension O-ring (2). Installation Procedure 1. Install a new O-ring (2) to the case extension. 2. Install the case extension (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the case extension bolts (3). ^ Tighten the case extension bolts (3) to 34 Nm (25 ft. lbs.). 4. Install the transmission support and the transmission mount. 5. Install the propeller shaft. 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 7459 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 7460 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 7461 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 7462 Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 4L60-E Pan Removal ........................................................................................... .......................................................................................................... 4.7L (5.0 Qt) Overhaul .............. .............................................................................................................................................................. ............................ 10.6L (11.0 Qt) 4L80-E Dry .................................................................................... ............................................................................................................................ 12.8L (13.5 Qt) Pan Removal .............................................................................................................................................. ....................................................... 7.8L (7.7 Qt) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 7465 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E Fluid - A/T: Service and Repair 4L60-E Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining field. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E > Page 7468 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E > Page 7469 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan bolts. ^ Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E > Page 7470 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E > Page 7471 Fluid - A/T: Service and Repair 4L80-E Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Remove the oil pan bolts. 5. Remove the oil pan. 6. Remove the gasket. 7. Remove the magnet. 8. Remove the oil filter. 9. Remove the filter neck seal. 10. The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. 11. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4L60-E > Page 7472 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan to the transmission with seventeen bolts. ^ Tighten the oil pan bolts to 11 Nm (97 inch lbs.). 6. Apply a small amount of sealant GM P/N 12346004 to the treads of the drain plug, if equipped. 7. Install the oil pan drain plug, if equipped. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E Fluid Filter - A/T: Service and Repair 4L60-E Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining field. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E > Page 7477 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E > Page 7478 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan bolts. ^ Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E > Page 7479 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E > Page 7480 Fluid Filter - A/T: Service and Repair 4L80-E Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Remove the oil pan bolts. 5. Remove the oil pan. 6. Remove the gasket. 7. Remove the magnet. 8. Remove the oil filter. 9. Remove the filter neck seal. 10. The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. 11. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E > Page 7481 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan to the transmission with seventeen bolts. ^ Tighten the oil pan bolts to 11 Nm (97 inch lbs.). 6. Apply a small amount of sealant GM P/N 12346004 to the treads of the drain plug, if equipped. 7. Install the oil pan drain plug, if equipped. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 7486 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 7487 Fluid Line/Hose: Technical Service Bulletins A/T - Cooler Line Fitting Applications Bulletin No.: 08-07-30-004 Date: January 31, 2008 INFORMATION Subject: 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70 M32, M33, MK2 MD6) Oil Cooler Fitting Change Models: 1997-2008 GM Light Duty Trucks (Including Saab) with 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70, M3, M33, MK2, MD6) Aluminum cooler line fittings - These new fittings (2) cannot be used on earlier cases because the threaded hole is not the same size. Old style fittings (1) will continue to be available through SPO parts. Service cases will be the new case and fittings. The old cases with the old thread design will not be maintained for service. The connection on the hose side will accept both the short snout and the newer longer snout cooler hose assemblies. The fittings (1) have a new torque specification of 20 N.m (14 lb ft). They also have one inner and one outer "0" ring that are not serviced separately. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 7488 The new thread size 9/16-1a UNF-2A (1) was implemented on 11-29-07 or Julian date 333. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 7489 Fluid Line/Hose: Specifications 4L60-E Transmission Oil Cooler Pipe Fitting ................................................................................................................................... 35.0-41.0 Nm (26-30 ft. lbs.) Cooler Pipe Connector ......................................................................................................................................................... 35.0-41.0 Nm (26-30 ft. lbs.) 4L80-E Cooler Pipe Connector Nut at Case and Radiator ................................................................................................................................. 38 Nm (28 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E Fluid Line/Hose: Service and Repair 4L60-E Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Pull the plastic cap back from the quick connect fitting. 3. Remove the cooling lines from the clips. 4. Remove the two retaining rings securing the two cooling lines to the transmission. 5. Use a bent tip screwdriver. 6. Pull on the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of the fitting. Discard the retaining ring. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E > Page 7492 7. Pull the cooling line straight out from the quick connect fitting. 8. Repeat this procedure to remove all the remaining cooling lines from quick connect fittings. 9. If equipped, remove the oil cooling lines from the auxiliary oil cooler. 10. Remove the oil cooling lines from the vehicle. Installation Procedure 1. Install the transmission oil cooler lines to the vehicle. Important: ^ Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. All retaining rings being installed must be new. ^ Ensure the following procedures are performed when installing the new retaining rings onto the fittings. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E > Page 7493 2. Install a NEW retaining ring (E-clip) into the quick connect fitting using the following procedure: 3. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 4. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 5. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 6. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. 7. Install the NEW retaining ring (E-clip) into the remaining quick connect fittings. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E > Page 7494 8. Install the cooler line into the quick connect fitting. 9. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 10. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 11. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. 12. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 13. Ensure that the plastic cap is fully seated against the fitting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E > Page 7495 14. Ensure that no gap is present between the cap and the fitting. 15. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. A hidden yellow identification band indicates proper joint seating. 16. Do not install the cooler line end into the fining incorrectly. 17. If you cannot position the plastic cap against the fitting, remove the retaining ring from the quick connect fitting. Check the retaining ring and the tube end in order to ensure neither is bent. Replace the cooler line or the retaining ring if necessary, and reinstall the cooler line per the installation procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E > Page 7496 18. Install the cooling lines to the transmission. 19. If equipped, install the oil cooling lines to the auxiliary oil cooler. 20. Install the cooling lines to the clips. 21. Ensure all of the protective plastic caps are positioned over all of the quick connect fittings. 22. Lower the vehicle. 23. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E > Page 7497 Fluid Line/Hose: Service and Repair 4L80-E Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Pull the plastic cap back from the quick connect fitting. 3. Remove the cooling lines from the clips. 4. Remove the two retaining rings securing the two cooling lines to the transmission. 5. Use a bent tip screwdriver. 6. Pull on the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of the fitting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E > Page 7498 Discard the retaining ring. 7. Pull the cooling line straight out from the quick connect fitting. 8. Repeat this procedure to remove all the remaining cooling lines from quick connect fittings. 9. If vehicle does not have an auxiliary transmission oil cooler, disconnect the cooling lines from the radiator. 10. If vehicle is equipped with an auxiliary oil cooler, disconnect the oil cooling lines from the auxiliary oil cooler. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E > Page 7499 11. For vehicles equipped with an auxiliary oil cooler, remove the oil cooling lines from the frame rail. Installation Procedure 1. Install the transmission oil cooler line to the vehicle. Important: ^ Do not reuse any of the oil lines or oil line fittings if there is excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. All retaining rings being installed must be new. ^ Ensure the following procedures are performed when installing the new retaining rings onto the fittings. 2. Install a NEW retaining ring (E-clip) into the quick connect fitting using the following procedure: 3. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 4. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E > Page 7500 5. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 6. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. 7. Install a NEW retaining ring (E-clip) into the remaining quick connect fittings. 8. Install the cooler line into the quick connect fitting. 9. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E > Page 7501 10. Install the cooler lines to the vehicle. 11. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 12. Pull back sharply, on the cooler line, in order to ensure that the cooler line is fastened into the quick connect fitting. 13. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 14. Ensure that the plastic cap is fully seated against the fitting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E > Page 7502 15. Ensure that no gap is present between the cap and the fitting. 16. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. A hidden yellow identification band indicates proper joint seating. 17. Do not install the cooler line end into the fitting incorrectly. 18. If you cannot position the plastic cap against the fitting, remove the retaining ring from the quick connect fitting. Check the retaining ring and the tube end in order to ensure neither is bent. Replace the cooler line or the retaining ring if necessary, and reinstall the cooler line per the installation procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E > Page 7503 19. For vehicles not equipped with an auxiliary oil cooler, install the cooling lines to the radiator. 20. For vehicles equipped with an auxiliary oil cooler, install the oil cooling lines to the auxiliary oil cooler. 21. For vehicles equipped with an auxiliary oil cooler, install the oil cooling lines to the frame rail. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E > Page 7504 22. Install the cooling lines to the transmission. 23. Install the cooling lines to the clips. 24. Ensure all of the protective plastic caps are positioned over all of the quick connect fittings. 25. Lower the vehicle. 26. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications 4L60-E Oil Pan to Transmission Case Bolt .................................................................................................................................................... 11 Nm (97 inch lbs.) Transmission Oil Pan to Case Bolt .......................................................................................................................................... 9.5-13.8 Nm (7-10 ft. lbs.) 4L80-E Oil Pan to Case ................................................................................................................................... .................................................. 24 Nm (18 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications 4L60-E Transmission Fluid Pressure Manual Valve Position Switch to Valve ................................................. ................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E A/T Fluid Pressure Manual Valve Position Switch Connector, Wiring Harness Side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E > Page 7513 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 7514 Fluid Pressure Sensor/Switch: Service and Repair For information relating to service of this component please refer to Valve Body; Service And Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Fluid Pump: Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7519 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7520 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7521 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7522 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7523 Fluid Pump: Technical Service Bulletins A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring Bulletin No.: 04-07-30-006 Date: February 11, 2004 INFORMATION Subject: 4L65-E, 4L60-E, 4L60 and 200-4R Automatic Transmission Oil Pump Spring First and Second Design Identification Models: 2004 and Prior Passenger Cars and Light Duty Trucks 2003-2004 HUMMER H2 with 4L65-E, 4L60-E, 4L60 or 200-4R Automatic Transmission The purpose of this bulletin is to identify the oil pump spring usage for the two different pump designs. Manufacturing of the first design oil pump springs ended December 15, 2003. Manufacturing of the second design oil pump spring began December 16, 2003 The first design oil pump springs (206) and (207) DO NOT have any identification markings. The first design springs (206) and (207) use an inner and outer spring, two springs. The second design oil pump spring (245) is identified with tapered ends on the spring (245) as shown above. The second design spring (245) is a single spring. When servicing either (first design or second design) oil pump body, use the new single oil pump spring (245) with tapered ends. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7524 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7525 Fluid Pump: Technical Service Bulletins A/T - 4L60-E Oil Pump Identification Bulletin No.: 03-07-30-056 Date: November 05, 2003 INFORMATION Subject: 4L60-E Automatic Transmission Oil Pump First And Second Design Identification Models: 1997-2002 Chevrolet Camaro 1997-2002 Pontiac Firebird 2002-2004 Cadillac Escalade, Escalade EXT 1997-1999 Chevrolet C/K Full Size Pickup 1997-2004 Chevrolet Astro, Blazer, Corvette, Express, S-10, Suburban 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Tahoe 2002-2004 Chevrolet Avalanche, TrailBlazer 2004 Chevrolet Colorado, SSR 1997-1999 GMC Suburban 1997-2001 GMC Jimmy 1997-2004 GMC Envoy, Safari, Savana, Sierra, Sonoma 1999-2004 GMC Denali 2000-2004 GMC Yukon, Yukon XL 2004 GMC Canyon 1997-2004 Oldsmobile Bravada 2003-2004 HUMMER H2 with 4L60-E Automatic Transmission (RPOs M30, M32, M33) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7526 The purpose of this bulletin is to identify the correct oil pump rotor (212) and slide (203) usage for the two different transmission oil pump designs. Manufacturing of the first design oil pump rotor (212) and slide (203) ended November 30, 2000. Manufacturing of the second design oil pump rotor (212) and slide (203) began December 1, 2000. Important: It is critical that the first and second design oil pump rotors and slides do not become intermixed. Do not use first design pump components with second design pump components. If the pump components from either design are intermixed, pump efficiency will be affected resulting in less than optimal pump performance. The first design oil pump rotor (212) and slide (203) DO NOT have any identification markings. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7527 The second design oil pump rotor (212) and slide (203) are identified with dimples (circular depression) as shown above. The rotor (212) has two dimples adjacent to the rotor drive tangs (1). The slide (203) has one dimple located on the spring tab (2). Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 7528 Fluid Pump: Specifications 4L60-E Pump Assembly to Case Bolt ............................................................................................................................................... 26.0-32.0 Nm (19-24 ft. lbs.) Pump Cover to Pump Body Bolt .......................................................................................................................................... 20.0-27.0 Nm (15-20 ft. lbs.) 4L80-E Pump Assembly to Case ..................................................................................................................... .................................................. 24 Nm (18 ft. lbs.) Pump Body to Cover ........................................... ................................................................................................................................. 24 Nm (18 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation The IPC displays the vehicle speed based on the vehicle speed signal from the PCM. The PCM converts the data from the vehicle speed sensor to a 4000 pulses/mile signal. The IPC uses the vehicle speed signal circuit from the PCM in order to calculate the vehicle speed. The speedometer defaults to 0 km/h (0 mph) if a malfunction in the vehicle speed signal circuit exists. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Specifications Parking Pawl: Specifications 4L80-E Parking Pawl Bracket to Case ............................................................................................................. .................................................. 24 Nm (18 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Specifications > Page 7540 Parking Pawl: Service and Repair Park Lock Pawl and Actuator Replacement (4L80-E) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the oil pan and filter. 3. Remove the park/neutral position switch. 4. Remove the manual shaft nut and the pin. 5. Remove the detent lever and the actuator assembly. 6. Remove the bolts and the parking pawl bracket. 7. Remove the parking pawl return spring. 8. Use the modified screw extractor in order to remove the plug. 9. Remove the parking pawl shaft retainer, the shaft and the pawl. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. 10. Remove the manual shaft. 11. Remove the manual shaft seal. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Specifications > Page 7541 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite or the equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator assembly. 7. Install actuator assembly over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. install the nut on the shaft. 11. Install the roll pin. Notice: Refer to Fastener Notice in Service Precautions. 12. Install the parking lock bracket with the two bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the park/neutral position switch. 14. Install the oil pan and filter. 15. Lower the vehicle. 16. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Specifications Pressure Regulating Solenoid: Specifications 4L60-E Pressure Control Solenoid Bracket to Valve Body Bolt ....................................................................... .......................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) 4L80-E Pressure Control Solenoid Bracket to Valve Body .............................................................................. ...................................................................................................................... 8 Nm (71 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E > Page 7547 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E Pressure Regulating Solenoid: Service and Repair 4L60-E Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7550 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7551 Pressure Regulating Solenoid: Service and Repair 4L80-E Pressure Regulator Replacement ^ Tools Required J 36850 Transjel Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 3. Remove the reverse boost valve bushing retainer ring (2). 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7552 1. Install the pressure regulator valve with J 36850. 2. Pre-assemble the following parts: ^ The reverse boost valve bushing ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission oil pan and the oil filter. 6. Lower the vehicle. 7. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 7561 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 7567 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7572 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7573 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7574 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7575 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7581 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7582 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7583 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 7584 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 7585 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 7586 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 7587 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E Seals and Gaskets: Service and Repair 4L60-E Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement ^ Tools Required J 43911 Selector Shaft Seal Remover - J 43909 Selector Shaft Seal installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the Park/Neutral Position (PNP) Switch. 3. Be sure that the jackscrew for J43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 4. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell. 5. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until it is seated at the bottom of the bore. 4. Install the PNP Switch. 5. Lower the vehicle. 6. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Transmission Extension Housing Rear Oil Seal Replacement Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E > Page 7590 Transmission Extension Housing Rear Oil Seal Replacement ^ Tools Required J 21426 Extension Housing Seal Installer - J 36850 Transmission Assembly Lubricant Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft. 4. Remove the case extension housing rear oil seal. Use a flat bladed tool and carefully pry the seal from the housing. 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Installation Procedure 1. Lubricate the inside diameter of the new seal with J 36850. 2. Use the J 21426 with a soft faced mallet to install the seal. 3. Install the seal to the extension housing. 4. Install the propeller shaft. 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E > Page 7591 Seals and Gaskets: Service and Repair 4L80-E Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement ^ Tools Required J 43911 Selector Shaft Seal Remover - J 43909 Selector Shaft Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the Park/Neutral Position (PNP) Switch. 3. Be sure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 4. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell. 5. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until it is seated at the bottom of the bore. 4. Install the PNP Switch. 5. Lower the vehicle. 6. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Transmission Extension Housing Rear Oil Seal Replacement Transmission Extension Housing Rear Oil Seal Replacement ^ Tools Required J 41505 Output Shaft Seal Installer - J 6125-1B Slide Hammer - J 23129 Universal Seal Remover - J 36850 Transmission Assembly Lubricant Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E > Page 7592 Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft. 4. Using the J 6125-1B (1) and the J23129 (2), remove the output shaft seal (3) from the extension housing (4). 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Installation Procedure 1. Lubricate the inside diameter of the new seal with J 36850. 2. Use the J 41505 (1) with a soft faced mallet to install the seal (2). 3. Install the seal (2) to the extension housing (3). 4. Install the propeller shaft. 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications 4L60-E Transmission Fluid Pressure Manual Valve Position Switch to Valve ................................................. ................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E A/T Fluid Pressure Manual Valve Position Switch Connector, Wiring Harness Side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E > Page 7599 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 7600 Fluid Pressure Sensor/Switch: Service and Repair For information relating to service of this component please refer to Valve Body; Service And Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Transmission Mode Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7605 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7606 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for voltage through the body wiring harness junction block. 7. This step tests for ground integrity at the splice pack. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7607 Transmission Mode Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7608 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7609 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for voltage through the body wiring harness junction block. 7. This step tests for ground integrity at the splice pack. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 4L60-E Park/Neutral Position Switch Screw .................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E > Page 7615 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E Transmission Position Switch/Sensor: Adjustments 4L60-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E > Page 7618 Transmission Position Switch/Sensor: Adjustments 4L80-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E Transmission Position Switch/Sensor: Service and Repair 4L60-E Park Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 7621 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 7622 Transmission Position Switch/Sensor: Service and Repair 4L80-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 7623 4. Position the tool J41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications 4L60-E Speed Sensor Retainer Bolt ................................................................................................................................................. 10.5-13.5 Nm (7.7-10 ft. lbs.) 4L80-E Speed Sensor and Bracket Assembly to Case .................................................................................................................................... 11 Nm (97 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E Vehicle Speed Sensor (VSS) Sensor Connector, Wiring Harness Side (4L60-E) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E > Page 7629 Transmission Speed Sensor: Diagrams 4L80-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E Transmission Speed Sensor: Service and Repair 4L60-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 7632 Transmission Speed Sensor: Service and Repair 4L80-E Vehicle Speed Sensor (VSS) Replacement- Input Vehicle Speed Sensor (VSS) Replacement- Input Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor (1) electrical connector. 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1) and the bracket assembly from the case. 5. Inspect the vehicle speed sensor assembly (1) for any evidence of damage. Installation Procedure. 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1) and the bracket assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector. 5. Lower the vehicle. Vehicle Speed Sensor (VSS) Replacement-Output Vehicle Speed Sensor (VSS) Replacement-Output Removal Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 7633 1. Raise the vehicle. Refer to Vehicle Lifting. Important: This procedure is for 2WD vehicles. If the vehicle is equipped with 4WD, the output speed sensor is located on the transfer case. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2) and the bracket assembly from the case. 5. Inspect the output speed sensor assembly (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2) and the bracket assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the output speed sensor electrical connector. 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Transmission Fluid Temperature (TFT) Sensor Connector, Wiring Harness Side (4L80-E) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Diagrams Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 7641 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the body control module bracket. 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator away from the steering column jacket assembly and the cable shift cam assembly. 6. Remove the automatic transmission shift lock control actuator. Installation Procedure 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket assembly and the cable shift cam assembly. 2. Connect the electrical connector 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 7642 3.1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. 3.2. Press on the adjuster block (2) to compress the internal adjuster spring, which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 4.1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 4.2. Depress the brake pedal to move the shift lever out of the park position. 4.3. The actuator will be energized. 4.4. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the body control module bracket. 6. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications 4L80-E Solenoid to Valve Body ....................................................................................................................... ............................................... 8 Nm (71 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E Shift Solenoid: Diagrams 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E > Page 7648 Shift Solenoid: Diagrams 4L80-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 7649 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 7650 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 7651 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 7652 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications Shifter A/T: Specifications 4L60-E Floor shift Control Bolt ......................................................................................................................... ............................................ 10 Nm (89 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > A/T - Slipping/Missed Shifts Diagnostic Tips Shift Cable: Technical Service Bulletins A/T - Slipping/Missed Shifts Diagnostic Tips File In Section: 07 - Transmission/Transaxle Bulletin No.: 01-07-30-043 Date: December, 2001 INFORMATION Subject: Diagnostic Tips for Slipping or Missing Second, Third and/or Fourth Gear Models: 2001-2002 Chevrolet Camaro, Corvette 2001-2002 Pontiac Firebird 2001-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Suburban, Tahoe, Yukon, Yukon XL) 2001-2002 Chevrolet and GMC G-Van Models (Express, Savana) 2001-2002 Chevrolet and GMC M/L-Van Models (Astro, Safari) 2001-2002 Chevrolet and GMC S/T Pickup and Utility Models (S10, Sonoma, Blazer, Jimmy) 2002 Chevrolet and GMC S/T Utility Models (New Style) (TrailBlazer, Envoy) 2002 Cadillac Escalade 2001-2002 Oldsmobile Bravada Recently, a study was completed to determine the causes of slipping/missing 2nd, 3rd or 4th gear in the 4L60/4L65-E transmission family. This study was conducted using transmissions which were determined by dealership technicians as having a slipping/missing shift. The transmissions used were from vehicles with less than 19,000 km (12,000 mi) and the slipping/missing shift condition was verified during a test drive by dealership personnel before the transmission was removed from the vehicle. Eight items were found to cause the majority of the slipping/missing shift concerns. These eight items are listed below in the order of frequency that they were found. ^ Chips in the servo feed oil passage, orifice # 7 in the spacer plate. ^ Cut forward clutch piston inner seal. ^ Cut 3/4 clutch piston outer seal. ^ Input housing orifice cup plug blown out. ^ Input housing cracked or broken. ^ Mislocated valve body to spacer plate check ball(s). ^ Case damaged at the 2nd clutch apply piston pin bore causing the pin to drag/stick in the bore. ^ Input housing air bleed orifice cup plug with a check ball that does not seal. In addition to the above items, a misadjusted shift cable has been found to cause these types of concerns. When attempting to correct a slipping/missing second, third or fourth gear, the items listed above should be inspected as possible causes. It is also important to reference the appropriate Service Information for additional possible causes of these concerns. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 7661 Shift Cable: Specifications 4L60-E Shift Cable Grommet Screw ............................................................................................................................................................. 1.7 Nm (15 inch lbs.) Shift Control Cable Attachment ............................................................................................................................................................ 20 Nm (15 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E Shift Cable: Adjustments 4L60-E Automatic Transmission Range Selector Cable Adjustment 1. Ensure that the steering column shift lever and the transmission manual shaft lever are in the park position. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Pull back the white plastic cover (1) on the center connector. 4. Pull up on the center tabs of the lock button (2). Important: This step must be performed correctly to avoid a misadjusted cable. Do not grasp the shift cable end (2) during this procedure. 5. Release the shift cable end (2) and allow the blue spring to tension/adjust the shift cable system. 6. Pull the white cover (3) on the shift cable end (1) back. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E > Page 7664 7. Push the natural colored lock button (2) down to engage the locking teeth on the shift cable end (1). 8. Release the white cover (1). 9. Verify the white cover (1) conceals the natural colored lock (2). 10. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be readjusted. 11. Test the transmission for proper shift operation. 12. If all of the gear positions cannot be achieved, the shift cable must be readjusted. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E > Page 7665 Shift Cable: Adjustments 4L80-E Automatic Transmission Range Selector Cable Adjustment 1. Ensure that the steering column shift lever and the transmission manual shaft lever are in the park position. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Pull back the white plastic cover (1) on the center connector. 4. Pull up on the center tabs of the lock button (2). Important: This step must be performed correctly to avoid a misadjusted cable. Do not grasp the shift cable end (2) during this procedure. 5. Release the shift cable end (2) and allow the blue spring to tension/adjust the shift cable system. 6. Pull the white cover (3) on the shift cable end (1) back. 7. Push the natural colored lock button (2) down to engage the locking teeth on the shift cable end (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E > Page 7666 8. Release the white cover (1). 9. Verify the white cover (1) conceals the natural colored lock (2). 10. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be readjusted. 11. Test the transmission for proper shift operation. 12. If all of the gear positions cannot be achieved, the shift cable must be readjusted. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E Shift Cable: Service and Repair 4L60-E A/T Range Selector Cable Replacement (Front/Column End) Automatic Transmission Range Selector Cable Replacement (Front/Column End) Important: The range selector cable is a two piece cable assembly. The front half (column end) or rear half (transmission end) of the range selector cable can be removed without removing the other end/half of the range selector cable assembly. Removal Procedure 1. Position the steering column shift lever to the park position. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Ensure the transmission manual shaft is positioned to mechanical park. 4. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). 5. Locate the center connector on the transmission range selector cable. 6. Pull back the white plastic cover (1) on the center connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7669 7. Pull up on the center tabs of the lock button (2). Important: Do not reuse the existing E-clip. Discard the removed E-clip. 8. Ensure that the steering column shift lever remained in the park position for the best possible access to the E-clip. Remove the E-clip by pulling radially on the center section of the E-clip. 9. Pull the range selector cable center connector ends apart. 10. Lower the vehicle and ensure that the steering column shift lever is still in the park position. 11. Remove the instrument panel knee bolster. 12. Pull back the carpet and insulation around the driver's area. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7670 13. Remove the cable end (1) from the steering column ball stud. 14. Remove the retainer (2) securing the cable to the steering column. 15. Depress the tangs and remove the cable from the steering column bracket. 16. Remove the bolt securing the cable support to the brace. Important: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. 17. Remove the range selector cable from the support. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7671 18. Remove the cable grommet from the floor panel. 19. Raise the vehicle. Refer to Vehicle Lifting. 20. Remove the two clips on the cable from the floor panel reinforcement. 21. Remove the cable from the clips on the transfer case, if equipped. 22. Remove the front half (column end) of the range selector cable assembly from the vehicle. Installation Procedure 1. Route the cable through the hole in the floor panel. 2. Install the cable to the clips on the transfer case, if equipped. 3. Install the two clips on the cable to the floor panel reinforcement. 4. Lower the vehicle. 5. Ensure that the steering column shift lever is in the park position. 6. Install the cable grommet to the floor panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7672 7. Install the cable to the steering column bracket. Ensure the tangs fully seat (snap) into the steering column bracket. 8. Install the retainer (2) securing the cable to the steering column. 9. Install the cable end (1) to the steering column ball stud. 10. Install the cable to the support. Notice: Refer to Fastener Notice in Service Precautions. 11. Install the bolt securing the cable support to the brace. ^ Tighten the bolts to 10 Nm (89 inch lbs.). 12. Install the carpet and insulation around the driver's area. 13. Install the instrument panel knee bolster. 14. Raise the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7673 15. Ensure that the transmission manual shaft lever is in the mechanical park position. 16. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). 17. The new front half (steering column end) of the cable will contain a new pre-installed E-clip. 18. Grasp the front half (cab end) of the transmission cable (1) in the left hand and the rear half (transmission end) of the transmission cable (2) in the right hand. 19. Align the outside diameter of cable (2) with the inside of the diameter of cable (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7674 20. Push the end of the cable (2) inside the end of cable (1) until the blue spring on cable (2) is fully compressed. Pushing together the two ends of the cable will engage the inner wire and lock both cable wires together. Important: This step must be performed correctly to avoid a misadjusted cable. Do not grasp the cable end (2) during this procedure. 21. Release the cable end (2) and allow the blue spring to tension/adjust the cable system. 22. Pull the white cover (3) on the cable end (1) back. 23. Push the natural colored lock button (2) down to engage the locking teeth on the cable end (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7675 24. Release the white cover (1). 25. Verify the white cover (1) conceals the natural colored lock (2). 26. If the white cover (1) does not conceal the natural colored lock (2), repeat the cable adjustment procedure. 27. Lower the vehicle and test the transmission for proper shift operation. 28. If all of the gear positions cannot be achieved, repeat the cable adjustment procedure. A/T Range Selector Cable Replacement (Rear/Transmission End) Automatic Transmission Range Selector Cable Replacement (Rear/Transmission End) Important: The range selector cable is a two piece cable assembly. The front half (column end) or rear half (transmission end) of the range selector cable can be removed without removing the other end/half of the range selector cable assembly. Removal Procedure 1. Position the steering column shift lever to the park position. 2. Raise the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7676 3. Ensure the transmission manual shaft is positioned to mechanical park. 4. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). 5. Locate the center connector on the transmission range selector cable. 6. Pull back the white plastic cover (1) on the center connector. 7. Pull up on the center tabs of the lock button (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7677 Important: Do not reuse the existing E-clip. Discard the removed E-clip. 8. Ensure that the steering column shift lever remained in the park position for the best possible access to the E-clip. Remove the E-clip by pulling radially on the center section of the E-clip. 9. Pull the range selector cable center connector ends apart. 10. Remove the retainer that secures the cable to the bracket. 11. Depress the tangs and remove the cable from the bracket. 12. Remove the cable to from the clips on the transfer case, if equipped. 13. Remove the rear half (transmission end) of the range selector cable from the vehicle. Installation Procedure 1. Install the rear half transmission end of the range selector cable to the vehicle. 2. Install the cable to the clips on the transfer case, if equipped. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7678 3. Align and install the cable to the bracket. 4. Install the retainer that secures the cable to the bracket. 5. Install a new E-clip to the front half (steering column end) of the cable. 6. Ensure that the transmission manual shaft lever is in the mechanical park position. 7. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). 8. Grasp the front half (steering column end) of the transmission cable (1) in the left hand and the rear half (transmission end) of the transmission cable (2) in the right hand. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7679 9. Align the outside diameter of cable (2) with the inside of the diameter of cable (1). 10. Push the end of the cable (2) inside the end of cable (1) until the blue spring on cable (2) is fully compressed. Pushing together the two ends of the cable will engage the inner wire and lock both cable wires together. Important: This step must be performed correctly to avoid a misadjusted cable. Do not grasp the cable end (2) during this procedure. 11. Release the cable end (2) and allow the blue spring to tension/adjust the cable system. 12. Pull the white cover (3) on the cable end (1) back. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7680 13. Push the natural colored lock button (2) down to engage the locking teeth on the cable end (1). 14. Release the white cover (1). 15. Verify the white cover (1) conceals the natural colored lock (2). 16. If the white cover (1) does not conceal the natural colored lock (2), repeat the cable adjustment procedure. 17. Lower the vehicle and test the transmission for proper shift operation. 18. If all of the gear positions cannot be achieved, repeat the cable adjustment procedure. A/T Range Selector Cable Bracket Replacement Automatic Transmission Range Selector Cable Bracket Replacement Removal Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7681 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Disconnect the transmission range selector cable from the shift lever and the bracket (2). 5. Remove the bolts (1) securing the transmission range selector cable bracket (2) to the transmission. 6. Remove the transmission range selector cable bracket from the vehicle. Installation Procedure 1. Install the transmission range selector cable bracket to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission range selector cable bracket bolts (1). ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 3. Install the transmission range selector cable to the bracket (2) and the lever. 4. Lower the vehicle. 5. Check the vehicle for proper operation. If adjustment of the cable is necessary, refer to Automatic Transmission Range Selector Cable Adjustment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7682 Shift Cable: Service and Repair 4L80-E A/T Range Selector Cable Replacement (Front/Column End) Automatic Transmission Range Selector Cable Replacement (Front/Column End) Important: The range selector cable is a two piece cable assembly. The front half (column end) or rear half (transmission end) of the range selector cable can be removed without removing the other end/half of the range selector cable assembly. Removal Procedure 1. Position the steering column shift lever to the park position. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Ensure the transmission manual shaft is positioned to mechanical park. 4. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). 5. Locate the center connector on the transmission range selector cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7683 6. Pull back the white plastic cover (1) on the center connector. 7. Pull up on the center tabs of the lock button (2). Important: Do not reuse the existing E-clip. Discard the removed E-clip. 8. Ensure that the steering column shift lever remained in the park position for the best possible access to the E-clip. Remove the E-clip by pulling radially on the center section of the E-clip. 9. Pull the range selector cable center connector ends apart. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7684 10. Lower the vehicle and ensure that the steering column shift lever is still in the park position. 11. Remove the instrument panel knee bolster. 12. Pull back the carpet and insulation around the driver's area. 13. Remove the cable end (1) from the steering column ball stud. 14. Remove the retainer (2) securing the cable to the steering column. 15. Depress the tangs and remove the cable from the steering column bracket. 16. Remove the bolt securing the cable support to the brace. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7685 Important: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. 17. Remove the range selector cable from the support. 18. Remove the cable grommet from the floor panel. 19. Raise the vehicle. Refer to Vehicle Lifting. 20. Remove the two clips on the cable from the floor panel reinforcement. 21. Remove the cable from the clips on the transfer case, if equipped. 22. Remove the front half (column end) of the range selector cable assembly from the vehicle. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7686 1. Route the cable through the hole in the floor panel. 2. Install the cable to the clips on the transfer case, if equipped. 3. Install the two clips on the cable to the floor panel reinforcement. 4. Lower the vehicle. 5. Ensure that the steering column shift lever is in the park position. 6. Install the cable grommet to the floor panel. 7. Install the cable to the steering column bracket. Ensure the tangs fully seat (snap) into the steering column bracket. 8. Install the retainer (2) securing the cable to the steering column. 9. Install the cable end (1) to the steering column ball stud. 10. Install the cable to the support. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7687 Notice: Refer to Fastener Notice in Service Precautions. 11. Install the bolt securing the cable support to the brace. ^ Tighten the bolts to 10 Nm (89 inch lbs.). 12. Install the carpet and insulation around the driver's area. 13. Install the instrument panel knee bolster. 14. Raise the vehicle. Refer to Vehicle Lifting. 15. Ensure that the transmission manual shaft lever is in the mechanical park position. 16. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). 17. The new front half (steering column end) of the cable will contain a new pre-installed E-clip. 18. Grasp the front half (cab end) of the transmission cable (1) in the left hand and the rear half (transmission end) of the transmission cable (2) in the right hand. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7688 19. Align the outside diameter of cable (2) with the inside of the diameter of cable (1). 20. Push the end of the cable (2) inside the end of cable (1) until the blue spring on cable (2) is fully compressed. Pushing together the two ends of the cable will engage the inner wire and lock both cable wires together. Important: This step must be performed correctly to avoid a misadjusted cable. Do not grasp the cable end (2) during this procedure. 21. Release the cable end (2) and allow the blue spring to tension/adjust the cable system. 22. Pull the white cover (3) on the cable end (1) back. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7689 23. Push the natural colored lock button (2) down to engage the locking teeth on the cable end (1). 24. Release the white cover (1). 25. Verify the white cover (1) conceals the natural colored lock (2). 26. If the white cover (1) does not conceal the natural colored lock (2), repeat the cable adjustment procedure. 27. Lower the vehicle and test the transmission for proper shift operation. 28. If all of the gear positions cannot be achieved, repeat the cable adjustment procedure. A/T Range Selector Cable Replacement (Rear/Transmission End) Automatic Transmission Range Selector Cable Replacement (Rear/Transmission End) Important: The range selector cable is a two piece cable assembly. The front half (column end) or rear half (transmission end) of the range selector cable can be removed without removing the other end/half of the range selector cable assembly. Removal Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7690 1. Position the steering column shift lever to the park position. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Ensure the transmission manual shaft is positioned to mechanical park. 4. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). 5. Locate the center connector on the transmission range selector cable. 6. Pull back the white plastic cover (1) on the center connector. 7. Pull up on the center tabs of the lock button (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7691 Important: Do not reuse the existing E-clip. Discard the removed E-clip. 8. Ensure that the steering column shift lever remained in the park position for the best possible access to the E-clip. Remove the E-clip by pulling radially on the center section of the E-clip. 9. Pull the range selector cable center connector ends apart. 10. Remove the retainer that secures the cable to the bracket. 11. Depress the tangs and remove the cable from the bracket. 12. Remove the cable to from the clips on the transfer case, if equipped. 13. Remove the rear half (transmission end) of the range selector cable from the vehicle. Installation Procedure 1. Install the rear half transmission end of the range selector cable to the vehicle. 2. Install the cable to the clips on the transfer case, if equipped. 3. Align and install the cable to the bracket. 4. Install the retainer that secures the cable to the bracket. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7692 5. Install a new E-clip to the front half (steering column end) of the cable. 6. Ensure that the transmission manual shaft lever is in the mechanical park position. 7. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). 8. Grasp the front half (steering column end) of the transmission cable (1) in the left hand and the rear half (transmission end) of the transmission cable (2) in the right hand. 9. Align the outside diameter of cable (2) with the inside of the diameter of cable (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7693 10. Push the end of the cable (2) inside the end of cable (1) until the blue spring on cable (2) is fully compressed. Pushing together the two ends of the cable will engage the inner wire and lock both cable wires together. Important: This step must be performed correctly to avoid a misadjusted cable. Do not grasp the cable end (2) during this procedure. 11. Release the cable end (2) and allow the blue spring to tension/adjust the cable system. 12. Pull the white cover (3) on the cable end (1) back. 13. Push the natural colored lock button (2) down to engage the locking teeth on the cable end (1). 14. Release the white cover (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7694 15. Verify the white cover (1) conceals the natural colored lock (2). 16. If the white cover (1) does not conceal the natural colored lock (2), repeat the cable adjustment procedure. 17. Lower the vehicle and test the transmission for proper shift operation. 18. If all of the gear positions cannot be achieved, repeat the cable adjustment procedure. A/T Range Selector Cable Bracket Replacement Automatic Transmission Range Selector Cable Bracket Replacement Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Disconnect the transmission range selector cable from the shift lever and the bracket (2). 5. Remove the bolts (1) securing the transmission range selector cable bracket (2) to the transmission. 6. Remove the transmission range selector cable bracket from the vehicle. Installation Procedure 1. Install the transmission range selector cable bracket to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E > Page 7695 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission range selector cable bracket bolts (1). ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 3. Install the transmission range selector cable to the bracket (2) and the lever. 4. Lower the vehicle. 5. Check the vehicle for proper operation. If adjustment of the cable is necessary, refer to Automatic Transmission Range Selector Cable Adjustment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: Customer Interest A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 7704 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 7705 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 7711 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 7712 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information > Page 7717 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 7722 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications 4L60-E TCC Solenoid Assembly to Case Bolt ..................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E Torque Converter Clutch Solenoid: Diagrams 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E > Page 7728 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E Torque Converter Clutch Solenoid: Service and Repair 4L60-E Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7731 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts, which retain the internal wiring harness. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7732 11. Using J28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7733 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts, which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7734 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7735 Torque Converter Clutch Solenoid: Service and Repair 4L80-E Torque Converter Clutch (TCC) Valve and Spring Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the oil filter. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 3. Remove the valve bore plug retainer ring (1). 4. Remove the following parts: ^ The valve bore plug ^ The TCC valve ^ The TCC valve spring Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 7736 1. Install the following parts: ^ The TCC valve spring ^ The TCC valve ^ The valve bore plug 2. Install the valve bore plug retainer ring (1). 3. Install the transmission oil pan and oil filter. 4. Lower the vehicle. 5. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Specifications Torque Converter Cover: Specifications 4L60-E Converter Cover Bolt ........................................................................................................................... ............................................. 10 Nm (89 inch lbs.) 4L80-E Flywheel Housing Cover to Transmission ........................................................................................................................................... 7 Nm (62 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7744 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7745 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7746 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7747 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7748 Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flushing Frequently Asked Questions File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-027 Date: June, 2003 INFORMATION Subject: Most Frequently Asked Questions and Answers for J 45096 TransFlow Transmission Oil Cooling System Flushing Machine Models: 2004 and Prior Passenger Cars and Light Duty Trucks with Automatic Transmission/Transaxle 2004 and Prior HUMMER H2 This bulletin is issued to help answer the most frequently asked questions and concerns about essential tool J 45096. Q: Why doesn't the machine work below 18°C (65°F)? A: The flow characteristics of ATF at temperatures below 18°C (65°F) does not provide accurate flow test results with the electronics used in the J 45096. Q: Why didn't the unit come with a tank heater? A: The vast majority of dealerships do not require a heater to keep the ATF above 18°C (65°F). As a result, the heater was deleted as a cost-savings measure. A tank heater, J 45096-10, is currently available from Kent-Moore if your dealership requires it. Refer to Corporate Bulletin Number 03-07-30-002A for suggestions on warming the ATF without using a heater blanket. Q: Why does the machine fail new oil coolers? A: Several reasons have been found. The most likely reason is the air pressure at the air hose connected to the J 45096 is less than 586 kPa (85 psi). Other reasons include a twisted hose inside the J 45096 at the bulkhead as a result of the nut turning when the waste or supply hose was installed, the internal pressure regulator was improperly set at the factory or a problem with the cooler lines on the vehicle. Perform the J 45096 self-test as described on pages 9 and 10 of the Operation Manual. If a problem is still detected, refer to Troubleshooting on page 19 of the Operation Manual. If a problem still persists, contact Kent-Moore Customer Service at 1-800-345-2233. Q: What is the difference between steel and aluminum oil coolers? A: The aluminum oil cooler tube is slightly thinner in construction than the steel oil cooler tube, which affects the oil flow rate. The fitting that is protruding out of the radiator tank easily identifies the aluminum oil cooler. Refer to the Quick Reference card provided with the J 45096 in order to identify the proper flow rate for the aluminum oil cooler. Q: Why can't I use TransFlow for Allison transmission cooling Systems? A: Validation of TransFlow is currently under development for light duty trucks equipped with the Allison automatic transmission. TransFlow is based on the existing MINIMUM flow rate specification through the transmission oil cooling system. The Allison transmission oil cooling system only has MAXIMUM oil flow rates specified and J 45096 does not have the capability to test the transmission oil cooling system at the maximum oil flow rate specification. Q: Why doesn't GM publish a specification for auxiliary transmission oil coolers? A: The auxiliary oil cooler used with GM vehicles does not contain an internal turbulator plate like the radiator tank oil cooler does. Therefore, there is no internal restriction that would affect the flow rate through the oil cooling system so a specification for auxiliary oil cooler is not required. Keep in mind, kinks and damage to the auxiliary cooler and lines can affect the flow rate through the system. Q: Why did GM drop the labor time for transmission repairs? A: The labor for flushing and flow testing the transmission oil cooling system is included with the R&R; labor of the "K" labor operations that require transmission removal. The time required to use the J 45096 to perform the flush and flow test is much less than that of the J 35944-A. The warranty labor savings allowed GM to provide the J 45096 at no cost to dealerships. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7749 Q: Why didn't the machine come with the adapters to hook up to the car? A: The J 45096 was designed to use the previously released essential cooler line adapters for the J 35944-A. All adapters are listed on page 17 of the Operation Manual and can be ordered from Kent-Moore at 1-800-345-2233. Q: How do I connect the J 45096 to a Catera, Prizm or a Vibe? A: These vehicles, along with many other models, only require barbed fittings to connect to the rubber cooler hose. These fittings are commercially available and already found in many shops. Q: Why didn't I receive an Operation Manual with the machine? A: The Operation Manual was packaged in the upper portion of the shipping carton. If the shipping carton was lifted off the base without opening the top of the carton, the Operation Manual could have been discarded with the carton. Replacement Operation Manual packages can be obtained from Kent-Moore Customer Service at 1-800-345-2233. Q: Why can't I re-use the transmission fluid I use for flushing? A: The very fine metal and clutch material debris from the transmission failure in the ATF causes failures with the hall effect speed sensors that are used to measure the flow rate. To avoid costly repairs, expensive filters, regular maintenance and problems caused by a partially restricted filter, the filter was not included. Q: What do I do if I need service on my machine? A: Call Kent-Moore Customer Service at 1-800-345-2233. The J 45096 has a one-year warranty. Q: Can I flush and flow engine oil coolers? A: The engine oil cooler flow rates, the appropriate adapters and an acceptable procedure are currently under development. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7750 Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 4L60-E Transmission Cooler: Service and Repair 4L60-E Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. ^ Tighten the bolts to 12 Nm (9 ft. lbs.). 3. Connect the transmission oil cooler lines to the auxiliary cooler. 4. Install the front grill assembly. 5. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 4L60-E > Page 7753 Transmission Cooler: Service and Repair 4L80-E Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. ^ Tighten the bolts to 12 Nm (106 inch lbs.). 3. Connect the transmission oil cooler lines to the auxiliary cooler. 4. Install the front grill assembly. 5. Fill the transmission to the proper level with Dexron III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Transmission Mode Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7758 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7759 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for voltage through the body wiring harness junction block. 7. This step tests for ground integrity at the splice pack. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7760 Transmission Mode Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7761 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7762 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for voltage through the body wiring harness junction block. 7. This step tests for ground integrity at the splice pack. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications Transmission Mount: Specifications 4L60-E Trans Mount to Transmission Bolt ....................................................................................................................................................... 25 Nm (18 ft. lbs.) 4L80-E Transmission Mount to Transmission Bolts ......................................................................................................................................... 25 Nm (18 ft. lbs.) Engine Rear Mount to Transmission Bolt ............................................................................................................................................. 44 Nm (32 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4L60-E Transmission Mount: Service and Repair 4L60-E Transmission Mount Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Remove the two nuts securing the transmission mount to the transmission support. 4. Raise the transmission off of the transmission support. 5. Remove the bolts (1). Raise the transmission just enough to remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4L60-E > Page 7768 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (1) that retain the transmission mount to the transmission (2WD), or transfer case adapter (4WD). ^ For vehicles equipped with 4WD, tighten the bolts to 47 Nm (35 ft. lbs.). ^ For vehicles equipped with 2WD, tighten the bolts to 50 Nm (37 ft. lbs.). 3. Lower the transmission and install the two nuts securing the transmission mount to the transmission support. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 4. Remove the transmission jack. 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4L60-E > Page 7769 Transmission Mount: Service and Repair 4L80-E Transmission Mount Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Remove the two nuts securing the transmission mount to the transmission support. 4. Raise the transmission off of the transmission support. 5. Remove the bolts (1). Raise the transmission just enough to remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4L60-E > Page 7770 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (1) that retain the transmission mount to the transmission (2WD), or transfer case adapter (4WD). ^ For vehicles equipped with 4WD, tighten the bolts to 47 Nm (35 ft. lbs.). ^ For vehicles equipped with 2WD, tighten the bolts to 50 Nm (37 ft. lbs.). 3. Lower the transmission and install the two nuts securing the transmission mount to the transmission support. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 4. Remove the transmission jack. 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 4L60-E Park/Neutral Position Switch Screw .................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E > Page 7776 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E Transmission Position Switch/Sensor: Adjustments 4L60-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E > Page 7779 Transmission Position Switch/Sensor: Adjustments 4L80-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E Transmission Position Switch/Sensor: Service and Repair 4L60-E Park Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 7782 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 7783 Transmission Position Switch/Sensor: Service and Repair 4L80-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 7784 4. Position the tool J41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Specifications Transmission Pressure Test Port: Specifications 4L80-E Oil Test Hole Plug ................................................................................................................................ ............................................. 11 Nm (97 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications 4L60-E Speed Sensor Retainer Bolt ................................................................................................................................................. 10.5-13.5 Nm (7.7-10 ft. lbs.) 4L80-E Speed Sensor and Bracket Assembly to Case .................................................................................................................................... 11 Nm (97 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E Vehicle Speed Sensor (VSS) Sensor Connector, Wiring Harness Side (4L60-E) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E > Page 7793 Transmission Speed Sensor: Diagrams 4L80-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E Transmission Speed Sensor: Service and Repair 4L60-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 7796 Transmission Speed Sensor: Service and Repair 4L80-E Vehicle Speed Sensor (VSS) Replacement- Input Vehicle Speed Sensor (VSS) Replacement- Input Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor (1) electrical connector. 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1) and the bracket assembly from the case. 5. Inspect the vehicle speed sensor assembly (1) for any evidence of damage. Installation Procedure. 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1) and the bracket assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector. 5. Lower the vehicle. Vehicle Speed Sensor (VSS) Replacement-Output Vehicle Speed Sensor (VSS) Replacement-Output Removal Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 7797 1. Raise the vehicle. Refer to Vehicle Lifting. Important: This procedure is for 2WD vehicles. If the vehicle is equipped with 4WD, the output speed sensor is located on the transfer case. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2) and the bracket assembly from the case. 5. Inspect the output speed sensor assembly (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2) and the bracket assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the output speed sensor electrical connector. 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Transmission Fluid Temperature (TFT) Sensor Connector, Wiring Harness Side (4L80-E) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: Customer Interest A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 > Page 7809 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 7819 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 7820 Valve Body Spring and Bore Plug Chart (inch) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 7821 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 7822 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 7823 Left Side Control Valve Body Assembly Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 7824 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 7825 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 7826 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: All Technical Service Bulletins A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 > Page 7831 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 7836 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 7837 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 7838 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 7848 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 7849 Valve Body Spring and Bore Plug Chart (inch) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 7850 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 7851 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 7852 Left Side Control Valve Body Assembly Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 7853 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 7854 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 7855 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 7860 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 7861 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 7862 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 7863 Valve Body: Specifications 4L60-E Valve Body to Case Bolt .......................................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) 4L80-E Control Valve Assembly to Case ....................................................................................................................................................... 11 Nm (97 inch lbs.) Valve Body to Case/Lube Pipe ......................................................................................................................................................... 11 Nm (97 inch lbs.) Valve Body to Case/TFP ......................................................................................... .......................................................................... 11 Nm (97 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E Valve Body: Service and Repair 4L60-E Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body from the transmission: ^ The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the oil pan, gasket, and filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E > Page 7866 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts. 10. Remove the TCC solenoid retaining bolts. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E > Page 7867 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the control valve body. 12. Reposition the harness to the side of the transmission case. 13. Remove the control valve body bolts, which retain the transmission fluid pressure switch to the control valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E > Page 7868 16. Remove the manual detent spring retaining bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. Important: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the control valve body passages. 19. Remove the remaining control valve body bolts. 20. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. Installation Procedure 1. Install the checkballs (1-7) in the valve body. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E > Page 7869 2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. 3. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E > Page 7870 Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. 5. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the control valve body bolts, which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ M8 X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) 6. Install the manual detent spring. 7. Install but do not tighten the manual detent spring retaining bolt. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E > Page 7871 8. Install the transmission fluid pressure switch. 9. Install but do not tighten the control valve body bolts, which retain the transmission fluid pressure switch to the control valve body. Notice: Refer to Fastener Notice in Service Precautions. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the control valve body bolts (in sequence) to 11 Nm (97 inch lbs.). 11. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the manual detent spring bolt to 11 Nm (97 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E > Page 7872 12. Install the TCC solenoid with a new O-ring seal to the valve body. 13. Install the TCC solenoid bolts. ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 15. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E > Page 7873 16. Install the TCC PWM solenoid (1) to the control valve body. 17. Install the TCC PWM solenoid retainer (2). 18. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the transmission fluid indicator stop bracket bolt to 11 Nm (97 inch lbs.). 19. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 20. Install the transmission ok pan and filter. 21. Lower the vehicle. 22. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E > Page 7874 Valve Body: Service and Repair 4L80-E Valve Body and Pressure Switch Replacement ^ Tools Required J 25025 Guide Pins - J 36350 Transjel Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body from the transmission: ^ The 2-3 solenoid (1) ^ The internal wiring harness (2) ^ The 1-2 shift solenoid (3) ^ The transmission fluid temperature sensor (4) ^ The transmission fluid pressure manual valve position switch (5) ^ The pressure control solenoid (6) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (7) 2. Remove the fluid level indicator. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the oil pan, gasket, and filter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E > Page 7875 5. Disconnect the internal wire harness from the transmission fluid pressure (TFP) manual valve position switch. Important: Use care not to loose the 5 O-rings that are located between the TFP manual valve position switch and the valve body. 6. Remove the control valve body bolts (1) that retain the (TFP) manual valve position switch (2) to the control valve body. 7. Remove the TFP manual valve position switch. 8. Disconnect the internal wiring harness electrical connectors from the remaining valve body electrical components. 9. Remove the lube oil pipe bolt (6) and retainer (7). 10. Remove the lube oil pipe (5). 11. Remove the bolts and remove the manual shaft detent spring (3). Important: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the transmission case passages. 12. Remove the remaining control valve body bolts. 13. Carefully lower the valve body down from the transmission case. Use care not to drop the manual shaft valve. 14. Remove the control valve assembly (2) which includes the following: ^ The accumulator housing assembly (1) ^ The control valve assembly to the spacer plate gasket ^ The spacer plate Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E > Page 7876 15. Remove the manual valve (1) from the control valve body. 16. inspect the manual valve for nicks and burrs. 17. Remove the spacer plate to case gasket (2) from the case. The gasket may stick to the spacer plate. 18. Remove the PWM screen (1) from the case passage. 19. Remove the manual 2-1 band servo assembly (1). 20. Remove the servo piston cushion spring (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E > Page 7877 21. Remove the manual 2-1 band servo piston pin retainer ring (4). 22. Remove the manual 2-1 band servo piston pin (1). 23. Remove the manual 2-1 band servo piston seal (2). Important: Do not use a magnet in order to remove the checkballs. Using a magnet to remove the checkballs may magnetize the checkballs, causing metal particles to stick. 24. Remove the eight checkballs (nine checkballs for some models). Installation Procedure 1. Install the 8 checkballs (9 checkballs for some models) into the control valve body. ^ The checkball marked as number 2, is used on RCP, RDP, ZJP and ALP models only ^ To hold the checkballs in place, use the J 36850. 2. Install the PWM screen into the control valve body. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E > Page 7878 3. Install a new manual 2-1 band servo piston seal (2) onto the manual 2-1 band servo piston (3). 4. Install the manual 2-1 band servo piston pin (1) into the manual 2-1 band servo piston (3). 5. Install the manual 2-1 band servo piston pin retainer ring (4). 6. Install the manual 2-1 band servo piston cushion spring (2). Important: Make certain that the tapered end of the manual 2-1 band servo piston pin contacts the manual 2-1 band. 7. Install the manual 2-1 band servo piston assembly (1). 8. Install the manual valve (1) into the control valve body. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E > Page 7879 9. To aid in alignment and assembly, install tool J 25025. 10. Install the control valve body gasket (6). 11. Install the control valve body assembly (5). Attach the manual valve to the detent lever while installing the control valve body assembly. 12. Install the transmission fluid pressure manual valve position switch (2). 13. Install the transmission fluid pressure manual valve position switch bolts (1) finger tight. 14. Tighten the bolts in the order shown to 11 Nm (97 inch lbs.). 15. Remove the J 25025. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E > Page 7880 16. Install the manual shaft detent roller and spring assembly (3) and bolts. 17. Install the two wiring harness clips (1) and bolts (2). 18. Install the wiring harness clip (1) and bolts (2). 19. Install the lube oil pipe (5) with the short end into the control valve body. 20. Install the lube oil pipe retainer (7) and the bolt (6). Notice: Refer to Fastener Notice in Service Precautions. 21. Install the control valve body bolts. ^ Tighten the bolts in the order shown to 11 Nm (97 inch lbs.). 22. Install the remaining control valve body bolts. ^ Tighten the remaining bolts to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness to the valve body electrical components 24. Install the oil pan, gasket, and filter. 25. Lower the vehicle. 26. Fill the transmission to the proper level using approved fluid. 27. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: Customer Interest Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's > Page 7889 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: All Technical Service Bulletins Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's > Page 7895 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > System Information > Technical Service Bulletins > M/T - Hydraulic Clutch Bleeding Procedure Improvement Clutch Hydraulic System: Technical Service Bulletins M/T - Hydraulic Clutch Bleeding Procedure Improvement Bulletin No.: 01-07-31-002B Date: November 01, 2006 INFORMATION Subject: Improved Bleeding Procedure for Hydraulic Clutch Release System Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2007 and Prior Chevrolet and GMC 6-7F T-Series Medium Duty Tilt Cab Models 2007 and Prior Isuzu F-Series Medium Duty Tilt Cab Models 2006-2007 HUMMER H3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-07-31-002A (Section 07 - Transmission/Transaxle). This bulletin is being issued to inform dealers of an improved procedure to aid in the ease of bleeding the clutch hydraulic system for the above listed vehicles. This procedure can be used anytime air is introduced into the hydraulic system. Following this procedure may also reduce the number of unnecessary parts replaced for low clutch pedal reserve and high shift effort. Verify that all the lines and fittings are dry and secure. Clean the dirt and grease from the reservoir cap in order to ensure that no foreign substances enter the system. Remove the reservoir cap. Fill the reservoir to the proper level with the required fluid. Attach the J 43485 (Adapter) to the J 35555 (Mity Vac), or equivalent. Brake fluid will deteriorate the rubber on J 43485. Use a clean shop cloth to wipe away the fluid after each use. Place and hold the adapter on the reservoir filler neck to ensure a tight fit. In some cases, the adapter will fit into the reservoir opening. Apply a vacuum of 51-68 kPa (15-20 hg) and remove the adapter. Refill the reservoir to the proper level. Repeat Steps 6 and 7. If needed, refill the reservoir and continue to pull a vacuum until no more bubbles can be seen in the reservoir or until the fluid level no longer drops. The vehicle will move if started in gear before the Actuator Cylinder is refilled and operational. Start the vehicle the first time in neutral to help prevent personal injury from vehicle movement and see if the transmission will shift easily into gear. Pump the clutch pedal until firm (to refill actuator cylinder). Add additional fluid if needed. Test drive vehicle to ensure proper operation. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Technical Service Bulletins > A/T - Shift Lock Control Feature Function Shift Interlock: Technical Service Bulletins A/T - Shift Lock Control Feature Function Bulletin No.: 03-07-30-043A Date: May 25, 2006 INFORMATION Subject: Information Regarding Automatic Transmission Shift Lock Control Function Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 03-07-30-043 (Section 07 - Transmission/Transaxle). This bulletin is being issued to better explain how the Automatic Transmission Shift Lock Control (formerly known as Brake Transmission Shift Interlock (BTSI)) feature is intended to operate. Revised wording regarding the shift lock control system began appearing in the Owner Manuals beginning with the 2004 model year. The shift lock control feature was intended to prevent drivers from shifting out of Park with the vehicle running without the brakes applied. However, if the ignition switch is in the Accessory (ACC) position, it may be possible on some vehicles to move the shift lever out of Park WITHOUT first activating the brake. The shift lock control system is ONLY active when the ignition switch is in the RUN or ON position. This means that when the ignition switch is in the RUN or ON position, the shift lever cannot be moved out of the Park position without activating the brake. Some owners may feel that the shift lock control system prevents an unattended child from moving the vehicle. Please stress to owners, as stated in the Owner Manual, that children should NEVER be left unattended in a vehicle, even if the ignition key has been removed from the vehicle. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Technical Service Bulletins > Customer Interest for Carrier Bearings: > 09-04-19-001 > Apr > 09 > Drivetrain - Whine or Click Type Noises from Front Axle Carrier Bearings: Customer Interest Drivetrain - Whine or Click Type Noises from Front Axle TECHNICAL Bulletin No.: 09-04-19-001 Date: April 28, 2009 Subject: Whine or Click Type Noises from Front Axle/New Design Front Axle Side Bearing Adjusters (Inspect/Replace with New Lock Rings) Models: 2002-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2002-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2009 GMC Sierra, Yukon, Yukon XL All Equipped with 8.25" Front Axle Condition Some customers may comment about whine or click type noises from the front axle. Upon further investigation, disassembly of the front differential may reveal chipped pinion or ring gear teeth. Cause This condition may be caused by an oversize front bearing side adjuster lock ring allowing the adjuster to move. New Design Lock Adjusters Vs Old Design T-Lock Adjusters Note Front axle housings for old-style (Classic - GMT800) and new-style (GMT900) vehicles are not interchangeable. The new design eliminates the side bearing adjusters movement. The lock adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. All front axle housings for all model years will use the new design adjusters, and use the new lock ring. The t-lock adjusters are still available, but if a housing replacement is needed, it is necessary to order the lock ring style housing, two of the new adjusters and two of the lock rings. Part numbers are available through the GM Parts catalog. A newly designed 8.25" front axle is in production. The new design eliminates the t-lock side bearing adjusters. The new adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. This design was phased into production during September, 2006. As a result, in the 2007 model year, both old-style (Classic - GMT800) and new-style (GMT900) vehicles built before the change have the t-lock design adjusters, and both types of vehicles built after the change have the lock ring design adjusters. Correction If no damage is visible and the concern was a whine or click noise, follow the inspect procedure in this bulletin and replace the lock ring. Complete assembly replacement is not necessary if an oversized slipping lock ring was found. Important The bearing adjuster lock rings are not reusable. Inspect New Replacement Part Prior to Installation Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Technical Service Bulletins > Customer Interest for Carrier Bearings: > 09-04-19-001 > Apr > 09 > Drivetrain - Whine or Click Type Noises from Front Axle > Page 7916 Replace the side bearing adjuster lock ring and refer to SI for adjustment. When replacing the side bearing adjuster lock ring, inspect the old locking ring and make sure there are vertical lines in the outer and inner diameter of the ring (1). Next inspect and make sure there is tension when the locking rings are installed. If the locking ring rotates freely around the adjuster, do not use the locking ring. Replace with a new locking ring and make the same inspection. Oversize Lock Rings-Do Not Use The new lock rings will not have any vertical lines (inner or outer). They are imprinted during install. If vertical lines are shown (1), DO NOT USE. Parts Information Refer to GM Parts Catalog. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carrier Bearings: > 09-04-19-001 > Apr > 09 > Drivetrain - Whine or Click Type Noises from Front Axle Carrier Bearings: All Technical Service Bulletins Drivetrain - Whine or Click Type Noises from Front Axle TECHNICAL Bulletin No.: 09-04-19-001 Date: April 28, 2009 Subject: Whine or Click Type Noises from Front Axle/New Design Front Axle Side Bearing Adjusters (Inspect/Replace with New Lock Rings) Models: 2002-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2002-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2009 GMC Sierra, Yukon, Yukon XL All Equipped with 8.25" Front Axle Condition Some customers may comment about whine or click type noises from the front axle. Upon further investigation, disassembly of the front differential may reveal chipped pinion or ring gear teeth. Cause This condition may be caused by an oversize front bearing side adjuster lock ring allowing the adjuster to move. New Design Lock Adjusters Vs Old Design T-Lock Adjusters Note Front axle housings for old-style (Classic - GMT800) and new-style (GMT900) vehicles are not interchangeable. The new design eliminates the side bearing adjusters movement. The lock adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. All front axle housings for all model years will use the new design adjusters, and use the new lock ring. The t-lock adjusters are still available, but if a housing replacement is needed, it is necessary to order the lock ring style housing, two of the new adjusters and two of the lock rings. Part numbers are available through the GM Parts catalog. A newly designed 8.25" front axle is in production. The new design eliminates the t-lock side bearing adjusters. The new adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. This design was phased into production during September, 2006. As a result, in the 2007 model year, both old-style (Classic - GMT800) and new-style (GMT900) vehicles built before the change have the t-lock design adjusters, and both types of vehicles built after the change have the lock ring design adjusters. Correction If no damage is visible and the concern was a whine or click noise, follow the inspect procedure in this bulletin and replace the lock ring. Complete assembly replacement is not necessary if an oversized slipping lock ring was found. Important The bearing adjuster lock rings are not reusable. Inspect New Replacement Part Prior to Installation Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carrier Bearings: > 09-04-19-001 > Apr > 09 > Drivetrain - Whine or Click Type Noises from Front Axle > Page 7922 Replace the side bearing adjuster lock ring and refer to SI for adjustment. When replacing the side bearing adjuster lock ring, inspect the old locking ring and make sure there are vertical lines in the outer and inner diameter of the ring (1). Next inspect and make sure there is tension when the locking rings are installed. If the locking ring rotates freely around the adjuster, do not use the locking ring. Replace with a new locking ring and make the same inspection. Oversize Lock Rings-Do Not Use The new lock rings will not have any vertical lines (inner or outer). They are imprinted during install. If vertical lines are shown (1), DO NOT USE. Parts Information Refer to GM Parts Catalog. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications Differential Case: Specifications Rear Drive Axle - Locking/Limited Slip Rear Axle Differential Case Screws (10.5" axle) ................................................................................................................................................... 17 Nm (13 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications Differential Cover: Specifications Rear Drive Axle Differential Housing Cover Bolts (All Axles) ...................................................................................................................................... 40 Nm (30 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Technical Service Bulletins > Customer Interest for Differential Axle Housing: > 03-04-19-003 > Jul > 03 > Drivetrain - Fluid Leak From Front of Vehicle Differential Axle Housing: Customer Interest Drivetrain - Fluid Leak From Front of Vehicle Bulletin No.: 03-04-19-003 Date: July 30, 2003 ADVANCED SERVICE INFORMATION Subject: Fluid Leak From Front of Vehicle (Add Teflon(R) Tape To Front Axle Vent/Plug Threads) Models: 2002-2003 Cadillac Escalade, Escalade EXT 2003 Cadillac Escalade ESV 2002-2003 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2003 GMC Denali, Denali XL, Sierra, Yukon, Yukon XL 2003 HUMMER H2 with All Wheel Drive or Four Wheel Drive Condition Some customers may comment on a fluid leak from the front of the vehicle. Diagnosis may lead to a concern of an axle fluid leak from the front axle vent connector assembly (or plug in an H2). In some cases, the vent/plug connector may be finger tight, or separated from the axle housing. Cause Some vent/plug connectors may exhibit a shrinkage after installation into the axle assembly, which occurs for a time during thermal cycling until it becomes dimensionally stable. Correction Replacing the vent/plug connector may not repair the vehicle in some cases because the new piece may also shrink. A vent connector with a new material that will not exhibit this condition will enter production in the 4th quarter of 2003. Until the new part number vent/plug connector assembly is available from SPO, follow the recommended procedure below. This bulletin will be revised when the new part number becomes available. Procedure Reseal the vent/plug connector assembly with Teflon(R) tape following these steps: 1. Remove the vent/plug connector from the axle assembly. 2. Remove the 0-ring from the vent/plug connector. Inspect the 0-ring for wear or cracks. 3. Wipe away any excess oil and debris with a clean cloth. 4. Mark the vent/plug connector on the flange in order to identify the starting point of the Teflon(R) tape. Important: ^ DO NOT tape the inner-most threads of the vent/plug. Excessive Teflon(R) tape may enter the front axle assembly possibly causing a seal leak. ^ DO NOT USE RTV Silicone on the vent/plug. 5. Wrap Teflon(R) tape three times around the vent/plug connector threads in a clockwise direction relative to the vane/oil side of the vent. Start and stop at the mark from step 4. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Technical Service Bulletins > Customer Interest for Differential Axle Housing: > 03-04-19-003 > Jul > 03 > Drivetrain - Fluid Leak From Front of Vehicle > Page 7937 6. Trim the excess Teflon(R) tape from the inner-most threads. Excessive Teflon(R) tape may enter the front axle assembly possibly causing a seal leak. 7. Reinstall the vent/plug connector 0-ring. Important: Do not over or under-tighten from this specification or a leak may occur. 8. Install the vent/plug connector back into the axle assembly. Tighten Tighten the vent/plug connector to 15-20 N.m (11-14 lb ft). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Axle Housing: > 03-04-19-003 > Jul > 03 > Drivetrain - Fluid Leak From Front of Vehicle Differential Axle Housing: All Technical Service Bulletins Drivetrain - Fluid Leak From Front of Vehicle Bulletin No.: 03-04-19-003 Date: July 30, 2003 ADVANCED SERVICE INFORMATION Subject: Fluid Leak From Front of Vehicle (Add Teflon(R) Tape To Front Axle Vent/Plug Threads) Models: 2002-2003 Cadillac Escalade, Escalade EXT 2003 Cadillac Escalade ESV 2002-2003 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2003 GMC Denali, Denali XL, Sierra, Yukon, Yukon XL 2003 HUMMER H2 with All Wheel Drive or Four Wheel Drive Condition Some customers may comment on a fluid leak from the front of the vehicle. Diagnosis may lead to a concern of an axle fluid leak from the front axle vent connector assembly (or plug in an H2). In some cases, the vent/plug connector may be finger tight, or separated from the axle housing. Cause Some vent/plug connectors may exhibit a shrinkage after installation into the axle assembly, which occurs for a time during thermal cycling until it becomes dimensionally stable. Correction Replacing the vent/plug connector may not repair the vehicle in some cases because the new piece may also shrink. A vent connector with a new material that will not exhibit this condition will enter production in the 4th quarter of 2003. Until the new part number vent/plug connector assembly is available from SPO, follow the recommended procedure below. This bulletin will be revised when the new part number becomes available. Procedure Reseal the vent/plug connector assembly with Teflon(R) tape following these steps: 1. Remove the vent/plug connector from the axle assembly. 2. Remove the 0-ring from the vent/plug connector. Inspect the 0-ring for wear or cracks. 3. Wipe away any excess oil and debris with a clean cloth. 4. Mark the vent/plug connector on the flange in order to identify the starting point of the Teflon(R) tape. Important: ^ DO NOT tape the inner-most threads of the vent/plug. Excessive Teflon(R) tape may enter the front axle assembly possibly causing a seal leak. ^ DO NOT USE RTV Silicone on the vent/plug. 5. Wrap Teflon(R) tape three times around the vent/plug connector threads in a clockwise direction relative to the vane/oil side of the vent. Start and stop at the mark from step 4. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Axle Housing: > 03-04-19-003 > Jul > 03 > Drivetrain - Fluid Leak From Front of Vehicle > Page 7943 6. Trim the excess Teflon(R) tape from the inner-most threads. Excessive Teflon(R) tape may enter the front axle assembly possibly causing a seal leak. 7. Reinstall the vent/plug connector 0-ring. Important: Do not over or under-tighten from this specification or a leak may occur. 8. Install the vent/plug connector back into the axle assembly. Tighten Tighten the vent/plug connector to 15-20 N.m (11-14 lb ft). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Technical Service Bulletins > Page 7944 Differential Axle Housing: Specifications Front Drive Axle Inner Axle Shaft Housing to Bracket Nuts ......................................................................................................................................... 100 Nm (75 ft. lbs.) Inner Axle Shaft Housing to Differential Carrier Assembly Bolts ............................................. ........................................................................................................................................................ 40 Nm (30 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Drain Plug, Differential > Component Information > Specifications Drain Plug: Specifications Front Drive Axle Plug, Drain and Fill .............................................................................................................................. ................................................ 33 Nm (24 ft. lbs.) Rear Drive Axle Drain Plug (All Axles) ........................................................................................................................... ............................................... 33 Nm (24 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Specifications Fill Plug: Specifications Front Drive Axle Plug, Drain and Fill .............................................................................................................................. ................................................ 33 Nm (24 ft. lbs.) Rear Drive Axle Fill Plug (All Axles) ............................................................................................................................... .............................................. 33 Nm (24 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update Fluid - Differential: Technical Service Bulletins Drivetrain - Front Drive Axle Lubrication Update Bulletin No.: 05-00-90-010 Date: December 07, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Drive Axle Carrier Lubricant Information Models: 1999-2005 Light Duty Trucks 2003-2005 HUMMER H2 2005 Saab 9-7X with Four-Wheel or All-Wheel Drive and Separate Front Drive Axle Carriers This bulletin is being issued to revise the front drive axle carrier lubricant specification in the Maintenance and Lubrication and the Front Drive Axle sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. This information also updates the information found in the Owner Manual. Important: Front drive axle carriers do not require periodic lubricant replacement. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update > Page 7955 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Front Drive Axle (8.25") ....................................................................................................................... ..................................................... 1.66 L (1.75 qts.) Front Drive Axle (9.25") ..................................... ....................................................................................................................................... 1.73 L (1.83 qts.) Rear Drive Axle (8.6") .................................................................................................................. ............................................................. 2.28 L (2.41 qts.) Rear Drive Axle (9.5") ............................... .................................................................................................................................................. 2.6 L (2.75 qts.) Rear Drive Axle (10.5") ...................................................................................................... ......................................................................... 2.6 L (2.75 qts.) Rear Drive Axle (11.5") ................... .......................................................................................................................................................... 3.62 L (3.83 qts.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 7958 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Differential Fluid Type Front (S4WD) Grade ........................................................................................................................... .................................................................................................. GL-5 Viscosity .................................. .............................................................................................................................................................. ................... 80W-90 Front (F4WD) Grade .......................................................................................... ............................................................................................................................. Synthetic Viscosity . .............................................................................................................................................................. .................................................... 75W-90 Rear Grade ....................................................................... ................................................................................................................................................ Synthetic Viscosity ............................................................................................................................... .................................................................................... 75W-90 Front Differential Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Grade ............................. .............................................................................................................................................................. ............................ Synthetic Viscosity .................................................................................................. ................................................................................................................. 75W-90 Front Drive Axle Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Grade ............................. .............................................................................................................................................................. ............................ Synthetic Viscosity .................................................................................................. ................................................................................................................. 75W-90 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications Pinion Bearing: Specifications Front Drive Axle Pinion bearing preload (New Bearings) ................................................................................................................................... 1.7-3.4 Nm (15-30 in.lbs.) Pinion bearing preload (Used Bearings) .................................................................................................................................... 1.1-2.8 Nm (10-25 in.lbs.) Pinion bearing and differential case bearing preload (New Bearings) .......................... ............................................................................................................................................... 3.4-6.2 Nm (30-55 in.lbs.) Pinion bearing and differential case bearing preload (Used Bearings) .................. ...................................................................................................................................................... 2.8-5.6 Nm (25-50 in.lbs.) Rear Drive Axle Bearing Cap Bolts (8.6" Axle) .............................................................................................................................................................. 75 Nm (55 ft. lbs.) Bearing Cap Bolts (9.5" Axle) .............................................................................................................................................................. 85 Nm (63 ft. lbs.) Bearing Cap Bolts (10.5" Axle) ......................................................................................................................................................... 185 Nm (136 ft. lbs.) Differential Bearing Adjuster Nut Lock Bolt (9.5" Axle) ..................................................................................................................... 26 Nm (19 ft. lbs.) Differential Bearing Adjuster Nut Lock Bolt (10.5" Axle) ................................................................................................................... 27 Nm (20 ft. lbs.) Pinion Bearing Cage Bolts (10.5" Axle) ............................................................................................................................................... 88 Nm (65 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Specifications Pinion Flange: Specifications Rear Drive Axle Axle Flange Bolts (10.5" Axle) ........................................................................................................................................................ 156 Nm (115 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications Ring Gear: Specifications Front Drive Axle Ring Gear Bolts ................................................................................................................................... ............................................... 120 Nm (88 ft. lbs.) Rear Drive Axle Ring Gear Bolts (8.6" Axle) ................................................................................................................. .............................................. 120 Nm (89 ft. lbs.) Ring Gear Bolts (9.5" Axle) ............................................................................................................................................................. 140 Nm (103 ft. lbs.) Ring Gear Bolts (10.5" Axle) ........................................................................................................................................................... 165 Nm (122 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Adjustments Axle Bearing: Adjustments REVISED WHEEL BEARING ADJ. (10.5" & 11.5" RING GEAR) Bulletin No.: 02-04-20-002 Date: May, 2002 IMPORTANT: Ensure the brakes are fully released and do not drag. ^ Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. 2. Remove the axle shaft. 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Adjustments > Page 7972 5. Tighten the wheel bearing adjusting nut using the J 2222-C. ^ Rotate the hub in the opposite direction to the way the adjuster nut is turning. ^ Ensure the inner bearing and the seal seats against the spindle shoulder. TIGHTEN ^ Adjusting nut to 70 Nm (52.0 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. IMPORTANT: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Adjustments > Page 7973 9. Install the retaining ring. 10. Install the axle shaft. 11. Inspect the lubricant level and add, if necessary. 12. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > Drivetrain - Revised Inner Drive Axle Joint Service Constant Velocity Joint: Technical Service Bulletins Drivetrain - Revised Inner Drive Axle Joint Service File In Section: 04 - Driveline Axle Bulletin No.: 03-04-18-003 Date: June, 2003 SERVICE MANUAL UPDATE Subject: Revised Wheel Drive Shaft Inner Joint and Seal Replacement Models: 2002-2003 Cadillac Escalade, Escalade EXT 2001-2003 Chevrolet Silverado, Suburban, Tahoe 2002-2003 Chevrolet Avalanche 2001-2003 GMC Sierra, Suburban, Yukon, Yukon XL 2003 HUMMER H2 with Four Wheel Drive This bulletin is being issued to revise the Wheel Drive Shaft Inner Joint and Seal Replacement procedure in the Rear Wheel Drive Shafts sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Wheel Drive Shaft Inner Joint and Seal Replacement Tools Required ^ J 35910 Seal Clamp Tool ^ J 36652 Drive Axle Clamp Swage Tool ^ J 36652-98 Axle Swage Tool Disassembly Procedure Important: Use caution when using the hand grinder by the tripot housing (1). 1. Use a hand grinder in order to cut through the swage ring (2). 2. Remove the tripot housing (1) from the halfshaft. 3. Wipe the grease off of the housing (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > Drivetrain - Revised Inner Drive Axle Joint Service > Page 7979 4. Thoroughly degrease the tripot housing (1). 5. Allow the tripot housing (1) to dry prior to assembly. 6. Using side cutters, remove the small boot retaining clamp. 7. Remove the following items from the halfshaft bar: 7.1. The spacer ring (1) 7.2. The tripot spider assembly (2) 7.3. The tripot boot (3) 8. Clean the halfshaft bar (4). Use a wire brush in order to remove any rust in the seal mounting area (grooves). 9. Inspect the needle rollers, needle bearings, and bearings. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate service kit. Assembly Procedure 1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Compress the joint seal (1) and small seal clamp (2) onto the halfshaft bar. 2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > Drivetrain - Revised Inner Drive Axle Joint Service > Page 7980 Notice: Refer to Fastener Notice in Cautions and Notices. 3. Secure the small seal clamp (1) with J 35910 (or equivalent), a breaker bar, and a torque wrench Tighten Tighten the small seal clamp (1) to 136 N.m (100 lb ft). 4. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Important: Assemble the tripot joint with the convolute retainer in the correct position, as illustrated. 5. Install the convolute retainer tool over the inboard joint seal, being sure to capture the following convolutions: ^ 2-5 for the 1500 model (except 1500HD) ^ 2-4 for the 1500HD, 2500, 3500, and HUMMER H2 models. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > Drivetrain - Revised Inner Drive Axle Joint Service > Page 7981 6. Install the tripot spider assembly (3) onto the halfshaft bar (2). 7. Install the spacer ring (1) in the groove at the end of the halfshaft bar (2). 8. Pack the tripot seal (4) and the tripot housing (1) with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > Drivetrain - Revised Inner Drive Axle Joint Service > Page 7982 9. Reassemble the tripot housing and the tripot seal using the following procedure: 9.1. Pinch the swage ring (2) slightly by hand in order to distort it into an oval shape. 9.2. Slide the distorted swage ring (2) over the large diameter of the seal. 9.3. Place the tripot housing over the spider assembly. 9.4. Install the seal onto the tripot housing. 9.5. Align the tripot seal (1), with the swage ring (2) in place, over the flat area on the tripot housing (3). 10. For the 1500 models (except 1500HD), assemble the bolts and the support plate to the base of the J-36652-01 and secure the base in a vise. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > Drivetrain - Revised Inner Drive Axle Joint Service > Page 7983 11. For the 1500HD, 2500, 3500, and HUMMER H2 models, assemble the bolts and the support plate to the base of the J 36652-98 and secure the base in a vise. 12. Inspect the inboard stroke position. ^ Use measurement A for the 1500 models (except 1500HD). ^ Use measurement B for the 1500HD, 2500, 3500, and HUMMER H2 models. 13. Position the inboard end (tripot end) of the halfshaft assembly into the base of the J-36652-01 for the 1500 models (except 1500HD) or J 36652-98 for the 1500HD, 2500, 3500 and HUMMER H2 models. 14. Install the top half of the J-36652-01 for the 1500 models (except 1500HD) or J 36652-98 for the 1500HD, 2500, 3500 and HUMMER H2 models. 15. Align the swage ring (2) and the swage ring clamp. 16. Insert the bolts. Tighten Hand tighten the bolts until the bolts are snug. Important: Align the following during this procedure: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > Drivetrain - Revised Inner Drive Axle Joint Service > Page 7984 ^ The tripot boot (3) ^ The tripot housing (1) ^ The swage ring (2) Tighten Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half. 17. Loosen the bolts and remove the halfshaft assembly from the tool. 18. Remove the convolute retainer tool from the boot. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement Constant Velocity Joint: Service and Repair Wheel Drive Shaft Inner Joint and Seal Replacement Wheel Drive Shaft Inner Joint and Seal Replacement ^ Tools Required J 8059 Snap Ring Pliers - J 35910 Seal Clamp Tool - J 36652 Split Plate Swage Clamp Disassembly Procedure Notice: With the removal of the wheel drive shaft for any reason, the transmission sealing surface (the tripot male/female shank of the joint) should be inspected for corrosion. If corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent in a rotational motion only. Do not clean with an oscillating motion. Transmission fluid may be used to clean off any remaining debris and the joint wiped dry before installation. Corrosion on the joint sealing surface may damage the transmission seals and cause a fluid leak. Important: Use caution when using the hand grinder by the tripot housing (1). 1. Use a hand grinder in order to cut through the swage ring (2). 2. Remove the tripot housing (1) from the halfshaft. 3. Wipe the grease off of the tripot assembly roller bearings and the tripot housing (1). 4. Thoroughly degrease the tripot housing (1). 5. Allow the tripot housing (1) to dry prior to assembly. Important: Handle the tripot spider assembly with care. Tripot balls and needle rollers may separate from the spider trunnion if the tripot balls and needle rollers are not handled carefully. Use side cutters to cut away the small seal clamp. 6. Compress the tripot seal up the halfshaft, away from the tripot spider assembly toward the outboard (CV joint assembly) end of the halfshaft. 7. Spread the spider spacer ring (2) with J 8059 (or equivalent). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 7987 8. Remove the following items from the halfshaft bar: 8.1. The spacer ring (1) 8.2. The spider assembly (2) 8.3. The tripot seal (3) 9. Clean the halfshaft bar (4). Use a wire brush in order to remove any rust in the seal mounting area (grooves). 10. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate service kit. Assembly Procedure 1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Compress the joint seal (1) and small seal clamp (2) onto the halfshaft bar. 2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar. Notice: Refer to Fastener Notice in Service Precautions. 3. Secure the small seal clamp (1) with J 35910 (or equivalent), a breaker bar, and a torque wrench. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 7988 ^ Tighten the small seal clamp (1) to 136 Nm (100 ft. lbs.). 4. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Important: Assemble the tripot joint with the convolute retainer in the correct position, as illustrated. 5. Install the convolute retainer tool over the inboard joint seal, being sure to capture the following convolutions: ^ 2-5 for the K1500 model. ^ 2-4 for the K2500, K3500, and Hummer 2 models. 6. Install the tripot spider assembly (3) onto the halfshaft bar (2). 7. Install the spacer ring (1) in the groove at the end of the halfshaft bar (2). 8. Pack the tripot seal (4) and the tripot housing (1) with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 7989 9. Reassemble the tripot housing and the tripot seal using the following procedure: 9.1. Pinch the swage ring (2) slightly by hand in order to distort it into an oval shape. 9.2. Slide the distorted swage ring (2) over the large diameter of the seal. 9.3. Place the tripot housing over the spider assembly. 9.4. Install the seal onto the tripot housing. 9.5. Align the tripot seal (1), with the swage ring (2) in place, over the flat area on the tripot housing (3). 10. Mount the base of J 36652 in a vise. 11. Check the inboard stroke position. ^ Use measurement A for the K1500 models. ^ Use measurement B for the K2500, K3500, and Hummer 2 models. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 7990 12. Position the inboard end (tripot end) of the halfshaft assembly into the base of J 36652. 13. Install the top half of J 36652. 14. Align the swage ring (2) and the swage ring clamp. 15. Insert the bolts. ^ Hand tighten the bolts in J 36652 until the bolts are snug. Important: Align the following during this procedure: ^ The tripot seal (3) ^ The housing (1) ^ The swage ring (2) ^ Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of J 36652 touch the bottom half of J 36652. 16. Loosen the bolts and remove the halfshaft assembly from J 36652. 17. Remove the convolute retainer tool from the seal. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 7991 Constant Velocity Joint: Service and Repair Wheel Drive Shaft Outer Joint and Seal Replacement Wheel Drive Shaft Outer Joint and Seal Replacement ^ Tools Required J 8059 Snap Ring Pliers - J 35910 Seal Clamp Tool - J 36652 Split Plate Swage Clamp Disassembly Procedure Notice: With the removal of the wheel drive shaft for any reason, the transmission sealing surface (the tripot male/female shank of the joint) should be inspected for corrosion. If corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent in a rotational motion only. Do not clean with an oscillating motion. Transmission fluid may be used to clean off any remaining debris and the joint wiped dry before installation. Corrosion on the joint sealing surface may damage the transmission seals and cause a fluid leak. 1. Place protective covers over the vise jaws. Place the halfshaft in the vise. Important: Use caution when using the hand grinder by the CV joint outer race (1). 2. Use a hand grinder to cut through the swage ring (2). 3. Use side cutters to cut off the small seal clamp (4). 4. Slide the seal (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 5. Wipe all grease away from the face of the CV joint. 6. Find the halfshaft bar retaining snap ring (3), which is located in the inner race (2). 7. Spread the snap ring ears apart using J 8059 (or equivalent). 8. Pull the CV joint (1) and the CV joint seal (5) from the halfshaft bar (4). 9. Discard the old CV joint seal (5). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 7992 10. Place a brass drift against the CV joint cage (1). 11. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 12. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 13. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 14. Repeat this process to remove all six of the balls. 15. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 16. Lift out the cage (4) and the inner race. 17. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 18. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 18.1. The inner and outer race assemblies 18.2. The CV joint cage 18.3. The chrome alloy balls 19. Dry all the parts. 20. Check the CV joint assembly for unusual wear, cracks, or other damage. 21. Replace any damaged parts. 22. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 7993 Assembly Procedure 1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. 3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). 5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. 6. Insert the cage (4) and inner race into the outer race (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 7994 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2). 11. Repeat this process in order to install all six of the balls. 12. Pack the CV joint seal (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small seal clamp (2) onto the CV joint seal (1). 14. Slide the CV joint seal (1) onto the halfshaft bar. 15. Position the small end of the CV joint seal (1) into the joint seal groove (3) on the halfshaft bar. 16. Secure the small seal clamp (1) using J 35910 (or equivalent), a breaker bar, and a torque wrench. ^ Tighten the small clamp (1) to 136 Nm (100 ft. lbs.). 17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 7995 18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the distorted swage ring (2) over the large diameter of the seal (1). Important: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation. Slide the CV joint (4) onto the halfshaft bar (3). The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint (4) is in the proper position. 20. Pull on the CV joint (4) to verify engagement. 21. Slide the large diameter of the CV joint seal (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4). 22. Clamp the CV joint seal (2) tightly to the CV joint outer race (1) with the large swage ring (4), using the following procedure: 23. Mount the base of J 36652 in a vise. 24. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of J 36652. 25. Align the following during this procedure: ^ The CV joint seal (3) ^ The CV joint assembly (1) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 7996 ^ The swage ring (2) 26. Install the top half of J 36652 onto the lower half of the tool, over the CV joint seal (3) and the CV joint assembly (1). 27. Align the swage ring (2) and the swage ring clamp. 28. Insert the bolts into J 36652. Hand tighten the bolts until the bolts are snug. ^ Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of J 36652 touch the bottom half of the tool. 29. Loosen the bolts and remove the halfshaft assembly from J 36652. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > Drivetrain - Revised Inner Drive Axle Joint Service Constant Velocity Joint Boot: Technical Service Bulletins Drivetrain - Revised Inner Drive Axle Joint Service File In Section: 04 - Driveline Axle Bulletin No.: 03-04-18-003 Date: June, 2003 SERVICE MANUAL UPDATE Subject: Revised Wheel Drive Shaft Inner Joint and Seal Replacement Models: 2002-2003 Cadillac Escalade, Escalade EXT 2001-2003 Chevrolet Silverado, Suburban, Tahoe 2002-2003 Chevrolet Avalanche 2001-2003 GMC Sierra, Suburban, Yukon, Yukon XL 2003 HUMMER H2 with Four Wheel Drive This bulletin is being issued to revise the Wheel Drive Shaft Inner Joint and Seal Replacement procedure in the Rear Wheel Drive Shafts sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Wheel Drive Shaft Inner Joint and Seal Replacement Tools Required ^ J 35910 Seal Clamp Tool ^ J 36652 Drive Axle Clamp Swage Tool ^ J 36652-98 Axle Swage Tool Disassembly Procedure Important: Use caution when using the hand grinder by the tripot housing (1). 1. Use a hand grinder in order to cut through the swage ring (2). 2. Remove the tripot housing (1) from the halfshaft. 3. Wipe the grease off of the housing (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > Drivetrain - Revised Inner Drive Axle Joint Service > Page 8001 4. Thoroughly degrease the tripot housing (1). 5. Allow the tripot housing (1) to dry prior to assembly. 6. Using side cutters, remove the small boot retaining clamp. 7. Remove the following items from the halfshaft bar: 7.1. The spacer ring (1) 7.2. The tripot spider assembly (2) 7.3. The tripot boot (3) 8. Clean the halfshaft bar (4). Use a wire brush in order to remove any rust in the seal mounting area (grooves). 9. Inspect the needle rollers, needle bearings, and bearings. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate service kit. Assembly Procedure 1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Compress the joint seal (1) and small seal clamp (2) onto the halfshaft bar. 2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > Drivetrain - Revised Inner Drive Axle Joint Service > Page 8002 Notice: Refer to Fastener Notice in Cautions and Notices. 3. Secure the small seal clamp (1) with J 35910 (or equivalent), a breaker bar, and a torque wrench Tighten Tighten the small seal clamp (1) to 136 N.m (100 lb ft). 4. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Important: Assemble the tripot joint with the convolute retainer in the correct position, as illustrated. 5. Install the convolute retainer tool over the inboard joint seal, being sure to capture the following convolutions: ^ 2-5 for the 1500 model (except 1500HD) ^ 2-4 for the 1500HD, 2500, 3500, and HUMMER H2 models. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > Drivetrain - Revised Inner Drive Axle Joint Service > Page 8003 6. Install the tripot spider assembly (3) onto the halfshaft bar (2). 7. Install the spacer ring (1) in the groove at the end of the halfshaft bar (2). 8. Pack the tripot seal (4) and the tripot housing (1) with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > Drivetrain - Revised Inner Drive Axle Joint Service > Page 8004 9. Reassemble the tripot housing and the tripot seal using the following procedure: 9.1. Pinch the swage ring (2) slightly by hand in order to distort it into an oval shape. 9.2. Slide the distorted swage ring (2) over the large diameter of the seal. 9.3. Place the tripot housing over the spider assembly. 9.4. Install the seal onto the tripot housing. 9.5. Align the tripot seal (1), with the swage ring (2) in place, over the flat area on the tripot housing (3). 10. For the 1500 models (except 1500HD), assemble the bolts and the support plate to the base of the J-36652-01 and secure the base in a vise. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > Drivetrain - Revised Inner Drive Axle Joint Service > Page 8005 11. For the 1500HD, 2500, 3500, and HUMMER H2 models, assemble the bolts and the support plate to the base of the J 36652-98 and secure the base in a vise. 12. Inspect the inboard stroke position. ^ Use measurement A for the 1500 models (except 1500HD). ^ Use measurement B for the 1500HD, 2500, 3500, and HUMMER H2 models. 13. Position the inboard end (tripot end) of the halfshaft assembly into the base of the J-36652-01 for the 1500 models (except 1500HD) or J 36652-98 for the 1500HD, 2500, 3500 and HUMMER H2 models. 14. Install the top half of the J-36652-01 for the 1500 models (except 1500HD) or J 36652-98 for the 1500HD, 2500, 3500 and HUMMER H2 models. 15. Align the swage ring (2) and the swage ring clamp. 16. Insert the bolts. Tighten Hand tighten the bolts until the bolts are snug. Important: Align the following during this procedure: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > Drivetrain - Revised Inner Drive Axle Joint Service > Page 8006 ^ The tripot boot (3) ^ The tripot housing (1) ^ The swage ring (2) Tighten Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half. 17. Loosen the bolts and remove the halfshaft assembly from the tool. 18. Remove the convolute retainer tool from the boot. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > Page 8007 Constant Velocity Joint Boot: Service and Repair Wheel Drive Shafts Boot Cover Replacement ^ Tools Required J 41187 Band-it Type Tool Disassembly Procedure Important: Be careful when removing the clamps from the halfshaft seal cover, If reusing the halfshaft seal cover. 1. Use side cutters to cut the halfshaft seal cover clamps (2) and the nylon strap (1). 2. Slide the halfshaft seal cover (1) off of the halfshaft, over the CV joint end. 3. Check the halfshaft seal cover (1) for rips, tears, worn spots or other damage. Reuse the halfshaft seal cover (1) if there is no damage visible. Assembly Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > Page 8008 1. Insert new clamps (3) into the original halfshaft seal cover (1) (if you are reusing the original halfshaft seal cover). 2. Slide the halfshaft seal cover (1) onto the halfshaft assembly (2), starting at the outboard (CV joint) end. 3. Align the inboard clamp (2) on the inboard joint (1). Align the seal cover seam so the seam is straight. Important: Tighten the seal cover clamp (1) as tight as possible without deforming the retaining clip. Clamps that are not tight enough allow the cover to slide upon the joint. This causes shortened service life. 4. Use J 41187 in order to tighten the inboard seal cover clamp (1). 5. Rotate J41187 toward the clip in order to bend the band onto the clip. 6. Pull on the tool's cutting handle in order to cut off the excess band. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > Page 8009 7. Pound the band flat between the latch tabs. Peen the latch tabs over in order to lock the band into position. 8. Twist the halfshaft seal cover (1): ^ K15 = 180 degrees ^ K25 = 90 degrees Important: Be sure that the inboard tab of the halfshaft seal cover (1) is 180 degrees opposite the outboard tab of the halfshaft seal cover (1) before proceeding. 9. Position the outboard end of the halfshaft seal cover (1) over the CV joint (2) flat. Important: Tighten the seal cover clamp (1) as tight as possible without deforming the retaining clip. Clamps that are not tight enough allow the cover to slide upon the joint. This causes shortened service life. 10. Use J 41187 in order to tighten the outboard cover clamp (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > Page 8010 11. Rotate J 41187 toward the clip in order to bend the band onto the clip. 12. Pull the tool's cutting handle in order to cut off the excess band. 13. Pound the band flat between the latch tabs. Peen the latch tabs over in order to lock the band into position. 14. Gather the halfshaft seal cover material at the center. Wrap the halfshaft seal cover (1) tightly with the nylon strap (2) provided in the kit. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 8024 Seals and Gaskets: By Symptom Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 8025 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 8026 Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Drive Train - Revised Wheel Bearing Adjustment Procedure Wheel Bearing: Technical Service Bulletins Drive Train - Revised Wheel Bearing Adjustment Procedure File In Section: 04 - Driveline Axle Bulletin No.: 02-04-20-002 Date: May, 2002 SERVICE MANUAL UPDATE Subject: Revised Wheel Bearing Adjustment Procedure Models: 2001-2002 Chevrolet and GMC C/K and G-Van Models with 10.5 and 11.5 Inch Axles This bulletin is being issued to revise the Wheel Bearing Adjustment procedure in the Rear Drive Axle sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within Service Information (SI). If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Wheel Bearing Adjustment Preliminary Inspection Important: Ensure the brakes are fully released and do not drag. Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement. 3. Remove the hub adjuster nut retaining ring. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Drive Train - Revised Wheel Bearing Adjustment Procedure > Page 8031 4. Remove the adjuster nut lock key. Notice: Refer to Fastener Notice in Cautions and Notices. 5. Tighten the wheel bearing adjusting nut using the J 2222-C. Rotate the hub in the opposite direction to the way the adjuster nut is turning. Ensure the inner bearing and the seal seats against the spindle shoulder. Tighten Tighten the adjusting nut to 70 N.m (52 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Drive Train - Revised Wheel Bearing Adjustment Procedure > Page 8032 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. Important: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. 9. Install the retaining ring. 10. Install the axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement. 11. Inspect the lubricant level and add, if necessary. Refer to Lubricant Level Check. 12. Lower the vehicle. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Page 8033 Wheel Bearing: Service and Repair "For information regarding this component please refer to wheel hub service and repair" Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Shaft Nut ............................................................................................................................ ................................................ 210 Nm (155 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Service and Repair Wheel Seal: Service and Repair "For information regarding this component please refer to wheel hub service and repair" Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Specifications Center Support: Specifications Center Bearing Mounting Bolt ............................................................................................................. .................................................... 40 Nm (30 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications Drive/Propeller Shaft: Specifications Propeller Shaft Fastener Tightening Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Front Propeller Shaft Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Front Propeller Shaft > Page 8050 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Page 8051 Drive/Propeller Shaft: Description and Operation Propeller Shaft Description and Operation The propeller shaft is a tube with universal joints at both ends that do not require periodic maintenance. The universal joints transmit power from the transfer case, or from the transmission output shaft, to the differential. Front Propeller Shaft Description The front propeller shaft transmits rotating force from the transfer case to the front differential when the transfer case is engaged. The front propeller shaft connects to the transfer case using a splined slip joint. One-Piece Propeller Shaft Description A one-piece propeller shaft uses a splined slip joint in order to connect the driveline to the transmission, or to the transfer case. Propeller Shaft Phasing Description The propeller shaft is designed and built with the yoke lugs, or the ears, in-line with each other. This produces the smoothest running shaft possible. A propeller shaft that is designed with built-in yoke lugs in-line is known as in-phase. An out-of-phase propeller shaft often causes vibration. The propeller shaft generates vibration from speeding up and from slowing down each time that the universal joint spins around. The vibration is similar to a person snapping a rope and watching the wave reaction flow to the end. An in-phase propeller shaft is similar to 2 persons snapping a rope at the same time and watching the waves meet and cancel each other. Canceling the vibration produces a smooth flow of power in the drive line. All splined shaft slip yokes are keyed in order to ensure proper phasing. Universal Joint Description The universal joint is connected to the propeller shaft. The universal joint consists of 4 caps with needle bearings and with grease seals. The caps and the seals are mounted on the trunnions of a cross or of a spider. The bearings and the caps are greased at the factory. No periodic maintenance is required. Two universal joints are used in a one-piece propeller shaft. Three universal joints are used in a two-piece propeller shaft. The bearings and the caps are pressed into the yokes. The bearings and the caps are held in place with snap rings, except for 2 bearings On some models. These bearings on some models are attached to the pinion flange of the differential. Universal joints handle the effects of various loads and of rear axle windup conditions during acceleration and braking. The universal joint operation is efficient and safe within the designed angle variations. When the design angle is exceeded, the operational life of the joint decreases. Center Bearing Description Center bearings support the driveline when using 2 or more propeller shafts. The center bearing is a ball bearing in a rubber cushion that attaches to a frame crossmember. The manufacturer lubricates the bearing and seals the bearing. The cushion allows vertical motion at the driveline and helps isolate the vehicle from vibration. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive/Propeller Shaft: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Propeller Shaft Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Propeller Shaft in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures/- Symptoms Propeller Shaft Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8054 Drive/Propeller Shaft: Symptom Related Diagnostic Procedures - Symptoms - Propeller Shaft Symptoms - Propeller Shaft Before beginning diagnosis, review the system description and operation in order to familiarize yourself with the system function. Classifying the Symptom Propeller Shaft symptoms can usually be classified into the following categories: ^ Leaks ^ Noises ^ Vibrations Leak and noise related symptoms are diagnosed within the Propeller Shaft section. For vibration related symptoms, refer to Diagnostic Starting Point - Vibration Diagnosis and Correction. Visual/Physical Inspection ^ Inspect the system for aftermarket devices, which could affect the operation of the Propeller Shaft. ^ Inspect the easily accessible or visible system components for obvious damage or conditions, which could cause the symptom. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: ^ Leak at Front Slip Yoke See: Leak at Front Slip Yoke ^ Universal Joint Noise See: Universal Joint Noise ^ Ping, Snap, or Click Noise See: Ping, Snap, or Click Noise ^ Knock or Clunk Noise See: Knock or Clunk Noise ^ Scraping Noise See: Scraping Noise ^ Squeak Noise See: Squeak Noise Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8055 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement- Front Drive/Propeller Shaft: Service and Repair Propeller Shaft Replacement- Front Propeller Shaft Replacement- Front ^ Tools Required J 43218 Clamp Pliers Narrow Jaw Removal Procedure Important: Before disassembly, observe and accurately mark all of the driveline components relative to the propeller shaft and to the axles. These items include the following components: ^ The propeller shafts ^ The wheel drive shafts ^ The pinion flanges ^ The output shafts Assemble all of the components in the exact relationship to each other prior to removal. Observe all published specifications and torque values, and any measurements obtained prior to disassembly. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Mark the relationship of the propeller shaft and of the front axle pinion yoke. 4. Remove the clamp (4) at the transfer case (3) by prying up the exposed end of the clamp (4) with a flat-bladed tool. 5. Remove the bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 6. Disconnect the propeller shaft (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Important: Do not drop the bearing cap assemblies of the yoke end. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement- Front > Page 8058 7. Remove the propeller shaft (5) from the transfer case output shaft by sliding the propeller shaft forward. Installation Procedure 1. Inspect the splines of the transfer case output shaft for a sufficient coating of lubricant. If the output shaft does not have a sufficient coating of lubricant, lubricate the shaft with lubricant GM P/N 12345879 (Canadian P/N 10953511) or with an equivalent lubricant meeting GM specification 9985830. 2. Install the new clamp into the groove of the propeller shaft boot. 3. Install the propeller shaft splines into the transfer case output shaft. 4. Install the propeller shaft (5) to the front axle pinion yoke (1). Align the reference marks that were made during removal. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the yoke retainers (7) and the bolts (6). ^ Tighten the yoke retainer bolts to 25 Nm (19 ft. lbs.). 6. Install the boot onto the transfer case output shaft until the boot is attached into the groove on the output shaft. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement- Front > Page 8059 7. Using the J 43218 crimp the clamp until the dimensions that are shown are obtained. 8. Install the transfer case shield, if equipped. 9. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement- Front > Page 8060 Drive/Propeller Shaft: Service and Repair Propeller Shaft Replacement- Rear Propeller Shaft Replacement- Rear Removal Procedure Important: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Reference mark the propeller shaft to the rear axle pinion yoke. 3. Reference mark the propeller shaft to the transmission or transfer case. 4. Remove the bolts (1) and the yoke retainers (2) from the rear axle pinion yoke (3). Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 5. Slide the propeller shaft forward in order to disconnect the propeller shaft from the rear axle pinion yoke. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement- Front > Page 8061 6. Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transmission or transfer case. 7. Remove the propeller shaft from the vehicle. Installation Procedure 1. Inspect the splines of the slip yoke for a sufficient coating of lubricant. If the splines of the slip yoke does not have a sufficient coating of lubricant, lubricate the shaft with lubricant GM P/N 12345879 (Canadian P/N 10953511) or with an equivalent lubricant meeting GM specification 9985830 (RWD w/ Automatic Transmission). 2. Install the propeller shaft into the transmission or transfer case. Align the reference marks made during removal. 3. Install the propeller shaft (3) to the rear axle pinion yoke (4). Align the reference marks made during removal. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the yoke retainers (2) and bolts (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement- Front > Page 8062 ^ Tighten the yoke retainer bolts to 25 Nm (19 ft. lbs.). 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 8063 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises Slip Yoke: Customer Interest Driveline - Bump/Clunk/Squawking Noises Bulletin No.: 01-04-17-004B Date: January 05, 2005 TECHNICAL Subject: Clunk, Bump or Squawk when Vehicle Comes to Complete Stop or Accelerating from Complete Stop (Replace Rear Drive Shaft Nickel-Plated Slip Yoke) Models Supercede: This bulletin is being revised to add Cadillac Escalade (Old Style) to the Models section. Please discard Corporate Bulletin Number 01-04-17-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a clunk, bump or squawk noise when the vehicle comes to a stop or when accelerating from a complete stop. Cause A slip/stick condition between the transfer case output shaft and the driveshaft slip yoke may cause this condition. Diagnostic Tips There are several resources in the electronic Service Information System which can provide the technician with information on diagnosis and repair of clunk conditions, and fix the customer's vehicle right the first time without unnecessary parts replacement. Some of the documents available in SI include: ^ Symptoms - Propeller Shaft Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8072 ^ Knock or Clunk Noise ^ Rear Drive Axle Noises (SI Document ID #700580) ^ Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin # 02-04-17-001 ^ Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin # 01-07-30-042 ^ Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin # 03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case. Note: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 6. Support the propeller shaft in a line horizontal with the table of a press. Important: Remove the front slip yoke and the universal joint together. The new nickel-plated slip yoke comes with a new universal joint. 7. Disassemble the snap rings by pinching the ends together with a pair of pliers. 8. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 9. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8073 10. Place the J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 11. If you do not completely remove the bearing cup, lift the cross and insert the J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 12. Rotate the propeller shaft. Press the opposite bearing cup out of the drive shaft yoke. 13. Remove the old slip yoke and universal joint. 14. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 15. Inspect the bearing cup bores for burrs or imperfections. 16. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. 17. Install the new nickel-plated slip yoke and universal joint. See parts table below for parts information. 18. Remove the bearing cups from the universal joint. 19. Assemble one bearing cup part way into one side of the yoke. Turn the yoke ear toward the bottom. 20. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8074 21. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 22. Install the opposite bearing cup part way into the yoke ear. 23. Ensure that the trunnions start straight and true into both bearing cups. 24. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 25. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 26. Assemble the bearing retainer in the retainer groove. 27. Continue pressing until both retainers can be snapped into place. 28. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a soft-faced dead blow hammer. 29. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. 30. Install the slip yoke onto the output shaft in the transfer case. 31. Align the reference marks on the pinion flange and the propeller shaft. 32. Install the yoke retainers and bolts. Tighten Tighten the yoke retainer bolts to 25 N.m (19 lb ft). 33. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8075 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8076 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8077 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8078 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8079 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8080 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8081 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises Slip Yoke: All Technical Service Bulletins Driveline - Bump/Clunk/Squawking Noises Bulletin No.: 01-04-17-004B Date: January 05, 2005 TECHNICAL Subject: Clunk, Bump or Squawk when Vehicle Comes to Complete Stop or Accelerating from Complete Stop (Replace Rear Drive Shaft Nickel-Plated Slip Yoke) Models Supercede: This bulletin is being revised to add Cadillac Escalade (Old Style) to the Models section. Please discard Corporate Bulletin Number 01-04-17-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a clunk, bump or squawk noise when the vehicle comes to a stop or when accelerating from a complete stop. Cause A slip/stick condition between the transfer case output shaft and the driveshaft slip yoke may cause this condition. Diagnostic Tips There are several resources in the electronic Service Information System which can provide the technician with information on diagnosis and repair of clunk conditions, and fix the customer's vehicle right the first time without unnecessary parts replacement. Some of the documents available in SI include: ^ Symptoms - Propeller Shaft Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8087 ^ Knock or Clunk Noise ^ Rear Drive Axle Noises (SI Document ID #700580) ^ Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin # 02-04-17-001 ^ Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin # 01-07-30-042 ^ Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin # 03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case. Note: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 6. Support the propeller shaft in a line horizontal with the table of a press. Important: Remove the front slip yoke and the universal joint together. The new nickel-plated slip yoke comes with a new universal joint. 7. Disassemble the snap rings by pinching the ends together with a pair of pliers. 8. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 9. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8088 10. Place the J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 11. If you do not completely remove the bearing cup, lift the cross and insert the J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 12. Rotate the propeller shaft. Press the opposite bearing cup out of the drive shaft yoke. 13. Remove the old slip yoke and universal joint. 14. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 15. Inspect the bearing cup bores for burrs or imperfections. 16. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. 17. Install the new nickel-plated slip yoke and universal joint. See parts table below for parts information. 18. Remove the bearing cups from the universal joint. 19. Assemble one bearing cup part way into one side of the yoke. Turn the yoke ear toward the bottom. 20. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8089 21. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 22. Install the opposite bearing cup part way into the yoke ear. 23. Ensure that the trunnions start straight and true into both bearing cups. 24. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 25. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 26. Assemble the bearing retainer in the retainer groove. 27. Continue pressing until both retainers can be snapped into place. 28. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a soft-faced dead blow hammer. 29. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. 30. Install the slip yoke onto the output shaft in the transfer case. 31. Align the reference marks on the pinion flange and the propeller shaft. 32. Install the yoke retainers and bolts. Tighten Tighten the yoke retainer bolts to 25 N.m (19 lb ft). 33. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8090 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8091 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8092 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8093 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8094 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8095 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8096 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Page 8097 Slip Yoke: Specifications Yoke Retainer Bolts ............................................................................................................................. ..................................................... 25 Nm (19 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring Universal Joint: Service and Repair Universal Joint Replacement - Nylon Injected Ring Universal Joint Replacement - Nylon Injected Ring ^ Tools Required J 9522-3 U Joint Bearing Separator - J 9522-5 U Joint Bearing Spacer Remover Disassembly Procedure Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 1. Support the propeller shaft in a line horizontal with the table of a press. 2. Mark the propeller shaft as to which end is the transmission end and which end goes to the rear axle. 3. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1 1/8 inch) socket. 4. In order to shear the plastic retaining ring on the bearing cup, place J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 5. If you do not completely remove the bearing cup, lift the cross and insert J 9522-5 between the seal and the bearing cup you are removing. Continue to press the bearing cup out of the yoke. 6. Rotate the propeller shaft. Press the opposite bearing cup out of the yoke. 7. Mark the orientation of the slip yoke to the tube for proper reassembly. 8. Remove the cross from the yoke. 9. Remove the remaining universal joint parts from the yoke. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner. 10. Inspect the retaining ring grooves for plastic. 11. Inspect the bearing cup bores in the yoke ears for burrs or imperfections. 12. Clean the remains of the sheared plastic bearing retainers from the grooves in the yoke. 13. The sheared plastic may prevent the bearing cups from pressing into place and thus prevent the bearing retainers from properly seating. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 8102 Assembly Procedure 1. Remove the bearing cups from the universal joint. 2. Assemble 1 bearing cup part way into 1 side of the yoke. 3. Turn the yoke ear toward the bottom. 4. Assemble the cross into the yoke so the trunnion seats freely into the bearing cup. 5. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 6. Assemble the opposite bearing cup part way into the yoke ear. 7. Ensure that the trunnions start straight and true into both bearing cups. 8. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for a free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hangup or binding, stop pressing, and inspect the needle bearings for misalignment in the bearing cup. 9. Press the bearing cup into the yoke until the bearing retainer groove clears the inside of the yoke. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 8103 10. Assemble the bearing retainer in the retainer groove. 11. Continue pressing until you can snap both retainers into place. 12. If seating the retainer is difficult, spring the yoke slightly with a firm blow from a dead blow hammer. 13. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so the snap ring seats in the bearing cup groove. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 8104 Universal Joint: Service and Repair Universal Joint Replacement- External Snap Ring Universal Joint Replacement- External Snap Ring ^ Tools Required J 9522-3 U-Joint Bearing Separator - J 9522-5 U-Joint Bearing Spacer Remover Disassembly Procedure Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 1. Support the propeller shaft in a line horizontal with the table of a press. 2. Mark the propeller shaft in order to show which end connects to the transmission and which end goes to the rear axle. 3. Disassemble the snap rings by pinching the ends together with a pair of pliers. 4. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 5. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 inch) hex head socket or a 27 mm (1-1/16 inch) socket. 6. Place J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 7. If you do not completely remove the bearing cup, lift the cross and insert J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 8. Rotate the propeller shaft. Press the opposite bearing cup out of the yoke. 9. Mark the orientation of the slip yoke to the tube for proper reassembly. 10. Remove the cross from the yoke. 11. Remove the remaining universal joint parts from the yoke. 12. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner. 13. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 14. Inspect the bearing cup bores for burrs or imperfections. 15. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 8105 prevent the bearing retainers from properly seating. Assembly Procedure 1. Remove the bearing cups from the universal joint. 2. Assemble 1 bearing cup part way into 1 side of the yoke. Turn the yoke ear toward the bottom. 3. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. 4. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 5. Install the opposite bearing cup part way into the yoke ear. 6. Ensure that the trunnions start straight and true into both bearing cups. 7. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 8. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 8106 9. Assemble the bearing retainer in the retainer groove. 10. Continue pressing until both retainers can be snapped into place. 11. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a dead blow hammer. 12. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Flywheel to Crankshaft Bolts Flex Plate: Specifications Flywheel to Crankshaft Bolts Engine Flywheel Bolt First Pass ............................................................................................................................................. .................................................. 20 Nm (15 ft. lbs.) Second Pass ....................................................... ................................................................................................................................... 50 Nm (37 ft. lbs.) Final Pass .................................................................................................................................... ........................................................ 100 Nm (74 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Flywheel to Crankshaft Bolts > Page 8111 Flex Plate: Specifications Flywheel to Torque Converter Bolts 4L60-E Flywheel to Torque Converter Bolt ...................................................................................................................................................... 63 Nm (46 ft. lbs.) 4L80-E Flywheel to Converter .......................................................................................................................... ................................................ 43 Nm (32 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 8112 Flex Plate: Service and Repair Engine Flywheel Replacement Removal Procedure 1. Remove the automatic transmission. Important: Note the position and direction of the engine flywheel before removal. 2. Remove the engine flywheel bolts. 3. Remove the automatic transmission engine flywheel. 4. Install two M11x1.5 mm bolts (1) to the threaded holes of the spacer, if applicable. 5. Rotate the bolts clockwise to remove the spacer. 6. Remove the spacer from the rear of the crankshaft, if applicable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 8113 Installation Procedure Important: The flywheel does not use a locating pin for alignment and will not initially seat against the crankshaft flange or spacer (if applicable), but will be pulled onto the crankshaft by the engine flywheel bolts. This procedure requires a three stage tightening process. - Certain applications (6.0L) require a spacer and longer bolts for proper flywheel position. 1. Install the spacer (if applicable) onto the rear of the crankshaft. 2. Install the automatic transmission engine flywheel to the crankshaft. Important: Longer flywheel bolts must be used on applications using a flywheel spacer. 3. Apply threadlock GM P/N 12345382, Canada P/N 10953489, or equivalent to the threads of the flywheel bolts. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 8114 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the engine flywheel bolts. 4.1. Tighten the engine flywheel bolts a first pass in sequence to 20 Nm (15 ft. lbs.). 4.2. Tighten the engine flywheel bolts a second pass in sequence to 50 Nm (37 ft. lbs.). 4.3. Tighten the engine flywheel bolts a final pass in sequence to 100 Nm (74 ft. lbs.). 5. Install the automatic transmission. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation The IPC displays the vehicle speed based on the vehicle speed signal from the PCM. The PCM converts the data from the vehicle speed sensor to a 4000 pulses/mile signal. The IPC uses the vehicle speed signal circuit from the PCM in order to calculate the vehicle speed. The speedometer defaults to 0 km/h (0 mph) if a malfunction in the vehicle speed signal circuit exists. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information > Technical Service Bulletins > Manual Transmission - M/T Operating Characteristics Manual Transmission/Transaxle: Technical Service Bulletins Manual Transmission - M/T Operating Characteristics INFORMATION Bulletin No.: 03-07-29-004G Date: December 15, 2010 Subject: Manual Transmission Operating Characteristics Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2009 and Prior Chevrolet and GMC Medium Duty Trucks 2006-2010 HUMMER H3 with Manual Transmission Supercede: This bulletin is being revised to add the 2011 model year and to add Cold Operation information. Please discard Corporate Bulletin Number 03-07-29-004F (Section 07 Transmission/Transaxle). Important Even though this bulletin attempts to cover operating characteristics of manual transmissions, it cannot be all inclusive. Be sure to compare any questionable concerns to a similar vehicle and if possible, with similar mileage. Even though many of the conditions are described as characteristics and may not be durability issues, GM may attempt to improve specific issues for customer satisfaction. The purpose of this bulletin is to assist in identifying characteristics of manual transmissions that repair attempts will not change. The following are explanations and examples of conditions that will generally occur in all manual transmissions. All noises will vary between transmissions due to build variation, type of transmission (usually the more heavy duty, the more noise), type of flywheel and clutch, level of insulation, etc. Basic Information Many transmission noises are created by the firing pulses of the engine. Each firing pulse creates a sudden change in angular acceleration at the crankshaft. These changes in speed can be reduced with clutch damper springs and dual mass flywheels. However, some speed variation will make it through to the transmission. This can create noise as the various gears will accel and decel against each other because of required clearances. Cold Operation Manual transmission operation will be affected by temperature because the transmission fluid will be thicker when cold. The thicker fluid will increase the amount of force needed to shift the transmission when cold. The likelihood of gear clash will also increase due to the greater time needed for the synchronizer assembly to perform its function. Therefore when the transmission is cold, or before it has reached operating temperature, quick, hard shifts should be avoided to prevent damage to the transmission. Gear Rattle Rattling or grinding (not to be confused with a missed shift type of grinding, also described as a combustion knock type of noise) type noises usually occur while operating the engine at low RPMs (lugging the engine). This can occur while accelerating from a stop (for example, a Corvette) or while operating at low RPMs while under a load (for example, Kodiak in a lower gear and at low engine speed). Vehicles equipped with a dual-mass flywheel (for example, a 3500 HD Sierra with the 6-speed manual and Duramax(R)) will have reduced noise levels as compared to vehicles without (for example, a 4500 Kodiak with the 6-speed manual and Duramax(R)). However, dual-mass flywheels do not eliminate all noise. Neutral Rattle There are often concerns of rattle while idling in neutral with the clutch engaged. This is related to the changes in angular acceleration described earlier. This is a light rattle, and once again, vehicles with dual mass flywheels will have reduced noise. If the engine is shut off while idling in neutral with the clutch engaged, the sudden stop of the engine will create a rapid change in angular acceleration that even dual mass flywheels cannot compensate. Because of the mass of all the components, this will create a noise. This type of noise should not be heard if the clutch is released (pedal pushed to the floor). Backlash Backlash noise is created when changing engine or driveline loading. This can occur when accelerating from a stop, coming to a stop, or applying and releasing the throttle (loading and unloading the driveline). This will vary based on vehicle type, build variations, driver input, vehicle loading, etc. and is created from the necessary clearance between all of the mating gears in the transmission, axle(s) and transfer case (if equipped). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information > Technical Service Bulletins > Manual Transmission - M/T Operating Characteristics > Page 8124 Shift Effort Shift effort will vary among different style transmissions and synchronizer designs. Usually the more heavy duty the transmission, the higher the shift effort because of the increased mass of the components. Shift effort can also be higher in cold weather because the fluid will be thicker. Medium duty transmissions will not shift as quickly as a Corvette transmission. To reduce shift effort, do not attempt to rush the shift - allow the synchronizers to work as designed. Shifting harder will only increase the chance of rushing past the synchronizer leading to grinding while shifting. Non-Synchronized Gears Some light duty truck transmissions in 1st gear (creeper-gear) and reverse gears in various transmissions, along with all gears in some medium duty transmissions, may be non-synchronized. This means there is not a mechanism to match input and output shaft speeds to allow for a smooth shift. This function is left up to the driver. This can be noticed if a shift into 1st or reverse is attempted while the vehicle is rolling or before the input shaft stops rotating leading to a gear grind. The grinding can be reduced by coming to a complete stop and pausing for a moment before shifting into the 1st or reverse gear. Some slight grinding can be expected. In medium duty non-synchronized transmissions, the driver must match input shaft (engine) speed to output shaft (driveshaft) speed with every shift. This can be accomplished by double clutching, or by using other methods. If the driver is not able to perform this function properly, there will be gear grinding with each improperly completed shift. Driver training may be required to correct this condition. Clutch brakes are used in medium duty non-synchronized transmissions to allow a shift into gear at a stop. The clutch brake is used to stop the input shaft from spinning, allowing a shift into gear at a stop without grinding. The clutch brake is activated by pressing the clutch pedal all the way to the floor. When the clutch brake is used, it is possible to have a blocked shift with the vehicle stationary. If this occurs, engage the clutch slightly to rotate the input gear to allow the shift. The clutch brake is intended to only be used while at a stop. Care must be taken to not activate the clutch brake while shifting between gears. This could lead to excessive grinding or a blocked or missed shift. Skip Shift Currently, the Cadillac CTS-V, Pontiac GTO, Chevrolet Corvette and Camaro SS (other models may follow) equipped with the 6-speed manual transmission have a feature referred to as a "skip-shift." This feature only allows a shift from 1st to 4th gear when the indicator lamp is illuminated on the dash. Dealers cannot disable this feature as it was established to help meet fuel economy standards. The conditions for this feature are: engine coolant at normal operating temperature, vehicle speed of 24-31 km/h (15-19 mph), 21% or less throttle being used (refer to Service Information or the Owner Manual for more details.) Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 8131 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 Control Module: Diagrams Transfer Case Shift Control Module - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 > Page 8134 Transfer Case Shift Control Module - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 > Page 8135 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8136 Control Module: Service and Repair Transfer Case Shift Control Module Replacement Removal Procedure 1. Remove the IP trim bezel. 2. Pull out the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly in order to disconnect the electrical connectors. 3. Disconnect all the electrical connectors from the lamp switch, cargo lamp and 4WD shift buttons assembly. 4. Remove the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly from the vehicle. 5. Remove the electrical harness retainer from the IP support beam. 6. Disconnect the 2 electrical connectors from the transfer case shift control module. 7. Move the electrical harness to the left side in order to make room to turn the transfer case shift control module. 8. Rotate the transfer case shift control module about 45 degrees counter clockwise while pulling out at the same time until the module is Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8137 approximately 90 degrees from the original position. 9. Pull out the module from the vehicle. Installation Procedure 1. Move the electrical harness to the left side in order to make room to install the transfer case shift control module. 2. Install the transfer case shift control module so that the electrical connector ports are to the right or pointing towards the instrument cluster. 3. While installing the transfer case shift control module rotate clockwise until the module is in place and the electrical connector ports are facing outwards. 4. Install the electrical harness retainer to the IP support beam. 5. Connect the 2 electrical connectors to the transfer case shift control module. 6. Install the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly the vehicle. 7. Connect all the electrical connectors to the lamp switch, cargo lamp and 4WD shift buttons assembly. 8. Install the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly in place. 9. Install the IP trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8138 10. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications 4L60-E Transmission Fluid Pressure Manual Valve Position Switch to Valve ................................................. ................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E A/T Fluid Pressure Manual Valve Position Switch Connector, Wiring Harness Side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E > Page 8146 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 8147 Fluid Pressure Sensor/Switch: Service and Repair For information relating to service of this component please refer to Valve Body; Service And Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Transmission Mode Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 8152 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 8153 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for voltage through the body wiring harness junction block. 7. This step tests for ground integrity at the splice pack. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 8154 Transmission Mode Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 8155 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 8156 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for voltage through the body wiring harness junction block. 7. This step tests for ground integrity at the splice pack. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 4L60-E Park/Neutral Position Switch Screw .................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E > Page 8162 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E Transmission Position Switch/Sensor: Adjustments 4L60-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E > Page 8165 Transmission Position Switch/Sensor: Adjustments 4L80-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E Transmission Position Switch/Sensor: Service and Repair 4L60-E Park Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 8168 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 8169 Transmission Position Switch/Sensor: Service and Repair 4L80-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 8170 4. Position the tool J41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications 4L60-E Speed Sensor Retainer Bolt ................................................................................................................................................. 10.5-13.5 Nm (7.7-10 ft. lbs.) 4L80-E Speed Sensor and Bracket Assembly to Case .................................................................................................................................... 11 Nm (97 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E Vehicle Speed Sensor (VSS) Sensor Connector, Wiring Harness Side (4L60-E) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E > Page 8176 Transmission Speed Sensor: Diagrams 4L80-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E Transmission Speed Sensor: Service and Repair 4L60-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 8179 Transmission Speed Sensor: Service and Repair 4L80-E Vehicle Speed Sensor (VSS) Replacement- Input Vehicle Speed Sensor (VSS) Replacement- Input Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor (1) electrical connector. 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1) and the bracket assembly from the case. 5. Inspect the vehicle speed sensor assembly (1) for any evidence of damage. Installation Procedure. 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1) and the bracket assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector. 5. Lower the vehicle. Vehicle Speed Sensor (VSS) Replacement-Output Vehicle Speed Sensor (VSS) Replacement-Output Removal Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 8180 1. Raise the vehicle. Refer to Vehicle Lifting. Important: This procedure is for 2WD vehicles. If the vehicle is equipped with 4WD, the output speed sensor is located on the transfer case. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2) and the bracket assembly from the case. 5. Inspect the output speed sensor assembly (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2) and the bracket assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the output speed sensor electrical connector. 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Transmission Fluid Temperature (TFT) Sensor Connector, Wiring Harness Side (4L80-E) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 02-04-21-004 > Apr > 02 > Transfer Case Switch `Service 4WD' Indicator ON Four Wheel Drive Selector Switch: Customer Interest Transfer Case Switch - `Service 4WD' Indicator ON File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-004 Date: April, 2002 TECHNICAL Subject: " "Service 4WD" Indicator Illuminated, DTC B2725 Set (Replace Transfer Case Shift Control Switch) Models: 1999-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Avalanche, Suburban, Tahoe, Yukon, Yukon XL) with Four Wheel Drive and NVG 236/246 Transfer Case (RPO NP8) Condition Some customers may comment on the Service 4WD indicator illuminating. Upon investigation, the technician may find DTC B2725 set. Cause The condition may be due to a intermittent fault in the transfer case shift control switch. Correction Important: The transfer case shift control module should not need replacement. DO NOT replace P/N 15749703 unless diagnosis points to the module as the malfunction. Replace the transfer case shift control switch using published Service Information procedures. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 02-04-21-004 > Apr > 02 > Transfer Case Switch - `Service 4WD' Indicator ON Four Wheel Drive Selector Switch: All Technical Service Bulletins Transfer Case Switch - `Service 4WD' Indicator ON File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-004 Date: April, 2002 TECHNICAL Subject: " "Service 4WD" Indicator Illuminated, DTC B2725 Set (Replace Transfer Case Shift Control Switch) Models: 1999-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Avalanche, Suburban, Tahoe, Yukon, Yukon XL) with Four Wheel Drive and NVG 236/246 Transfer Case (RPO NP8) Condition Some customers may comment on the Service 4WD indicator illuminating. Upon investigation, the technician may find DTC B2725 set. Cause The condition may be due to a intermittent fault in the transfer case shift control switch. Correction Important: The transfer case shift control module should not need replacement. DO NOT replace P/N 15749703 unless diagnosis points to the module as the malfunction. Replace the transfer case shift control switch using published Service Information procedures. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Transfer Case Shift Control Switch - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Transfer Case Shift Control Switch - C1 > Page 8200 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 8201 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel bezel trim piece. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. 1. Install the transfer case driver control switch into the instrument panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 8202 2. Install the instrument panel trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Page 8207 Speed Sensor: Specifications Transfer Case Speed Sensors ............................................................................................................ ........................................................ 15 Nm (11 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 8210 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) Speed Sensor: Service and Repair NVG 149-NP (One Speed Automatic) Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the electrical connector from the speed sensor. 3. Remove the speed sensor from the transfer case. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8213 1. Install the right rear speed sensor into the transfer case. ^ Tighten the right rear speed sensor to 31 Nm (23 ft. lbs.). 2. Install the electrical connector to the speed sensor. 3. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8214 Speed Sensor: Service and Repair NVG 236/246-NP8 (Two Speed Automatic) Transfer Case Speed Sensor Replacement (Front) Transfer Case Speed Sensor Replacement (Front) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield. 3. Remove the transfer case front speed sensor electrical connector. 4. Remove the transfer case front speed sensor. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8215 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case front speed sensor into the transfer case. ^ Tighten the transfer case front speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case front speed sensor electrical connector. 3. Install the transfer case shield. 4. Lower the vehicle. Refer to Vehicle Lifting. Transfer Case Speed Sensor Replacement (Right Rear) Transfer Case Speed Sensor Replacement (Right Rear) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8216 2. Remove the transfer case right rear electrical connector. 3. Remove the transfer case right rear speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case right rear speed sensor to the transfer case. ^ Tighten the transfer case right rear speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case right rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Transfer Case Speed Sensor Replacement (Left Rear) Transfer Case Speed Sensor Replacement (Left Rear) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case left rear speed sensor electrical connector. 3. Remove the transfer case left rear speed sensor. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8217 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case left rear speed sensor into the transfer case. ^ Tighten the transfer case left rear speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case left rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications NVG 149-NP (One Speed Automatic) Transfer Case Motor/Encoder Bolts ..................................................................................................................................................... 20 Nm (14 ft. lbs.) NVG 236/246-NP8 (Two Speed Automatic) Transfer Case Motor/Encoder Bolts ..................................................................................................................................................... 20 Nm (15 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Front Axle Actuator Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Front Axle Actuator > Page 8225 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Front Axle Actuator > Page 8226 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8227 Transfer Case Actuator: Service and Repair Transfer Case Motor/Encoder Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield. 3. Remove the front propeller shaft. 4. Remove the motor/encoder electrical connectors. 5. Remove the motor/encoder mounting bolts. 6. Remove the motor/encoder assembly. 7. Remove the motor/encoder gasket. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8228 Important: ^ If the motor/encoder assembly is being replaced because it is defective, make sure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench if necessary. ^ When installing the motor/encoder unit to the transfer case, make sure that the transfer case is indexed properly and it is flat against the transfer case before tightening the mounting bolts. 1. Install the NEW motor/encoder gasket to the transfer case. 2. Install the motor/encoder to the transfer case. Notice: Refer to Fastener Notice in Service Precautions. 3. Install motor/encoder mounting bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 4. Install the motor/encoder electrical connector. Ensure that the retention clips activate. 5. Install the front propeller shaft. 6. Install the transfer case shield. 7. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Specifications Case Adapter: Specifications NVG 149-NP (One Speed Automatic) Transfer Case to Transfer Case Adapter Nuts ...................................................................................................................................... 50 Nm (36 ft. lbs.) Transfer Case Adapter to Transmission Bolts ...................................................................................................................................... 50 Nm (36 ft. lbs.) NVG 236/246-NP8 (Two Speed Automatic) Transfer Case to Transfer Case Adapter Nuts ...................................................................................................................................... 50 Nm (36 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) Case Adapter: Service and Repair NVG 149-NP (One Speed Automatic) Transfer Case Adapter Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case from the vehicle. 3. Support the transmission with a suitable jack stand. 4. Remove the rear crossmember from the frame. 5. Remove the mounting bolts from the adapter to the transmission. 6. Remove the adapter from the transmission (automatic shown). 7. Remove the seal between the transfer case and the adapter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8234 8. Remove the gasket from the adapter. Installation Procedure Important: Always use a new gasket and seal for the adapter. Do not use any type of sealant or adhesive in place of or with the gasket or the seal. 1. Install the new seal on the adapter. Important: The transfer case adapter must be installed so that the adapter is evenly seated to the transmission before installing the retaining nuts. 2. Install the adapter to the transmission. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the adapter mounting bolts to the transmission. ^ Tighten the mounting bolts to 50 Nm (36 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8235 Important: When installing the gasket to the adapter, make sure that the yellow printing on the gasket is facing toward the transfer case (away from the transmission). The locating tab on the gasket should always be pointing up. 4. Install the new gasket to the adapter. 5. Install the transfer case to the adapter. 6. Install the crossmember in the vehicle. ^ Tighten the mounting bolts to 70 Nm (51 ft. lbs.). 7. Remove the transmission jack from the transmission. 8. Check the fluid level of the transfer case. 9. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8236 Case Adapter: Service and Repair NVG 236/246-NP8 (Two Speed Automatic) Transfer Case Adapter Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case assembly. 3. Support the transmission with a suitable jack stand. 4. Remove the transmission mount retaining nuts. 5. Raise the transmission assembly just high enough to remove the transmission mount. 6. Remove the transmission support mounting bolts. 7. Remove the transmission support from the frame. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8237 8. Remove the transmission mount bolts. 9. Remove the transmission mount. 10. Lower the transmission assembly slightly to gain access to the transfer case to the transmission bolts. 11. Remove the transfer case adapter mounting bolts. 12. Remove the transfer case adapter. 13. Remove the transfer case seal. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8238 14. Remove the transfer case gasket. Installation Procedure Important: If the gasket or the seal for the transfer case adapter becomes damaged, replace it. DO NOT use any type of silicone sealer or liquid gasket maker in place of the seal or gasket. 1. Install the new transfer case adapter seal. 2. Install the transfer case adapter to the transmission. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the transfer case adapter mounting bolts. ^ Tighten the transfer case adapter mounting bolts to 50 Nm (34 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8239 4. Install the transmission mount. 5. Install the transmission mount bolts. ^ Tighten the transmission mount bolts to 47 Nm (35 ft. lbs.). 6. Install the transmission support to the frame. 7. Install the transmission support mounting bolts. ^ Tighten the transmission support mounting bolts to 70 Nm (51 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8240 8. Install the transmission mount retaining nuts. ^ Tighten the transmission mount retaining nuts to 40 Nm (29 ft. lbs.). 9. Remove the transmission jack from the transmission. 10. Install the new transfer case gasket. 11. Install the transfer case assembly. 12. Check the transfer case fluid level. 13. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 8245 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 Control Module: Diagrams Transfer Case Shift Control Module - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 > Page 8248 Transfer Case Shift Control Module - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 > Page 8249 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8250 Control Module: Service and Repair Transfer Case Shift Control Module Replacement Removal Procedure 1. Remove the IP trim bezel. 2. Pull out the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly in order to disconnect the electrical connectors. 3. Disconnect all the electrical connectors from the lamp switch, cargo lamp and 4WD shift buttons assembly. 4. Remove the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly from the vehicle. 5. Remove the electrical harness retainer from the IP support beam. 6. Disconnect the 2 electrical connectors from the transfer case shift control module. 7. Move the electrical harness to the left side in order to make room to turn the transfer case shift control module. 8. Rotate the transfer case shift control module about 45 degrees counter clockwise while pulling out at the same time until the module is Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8251 approximately 90 degrees from the original position. 9. Pull out the module from the vehicle. Installation Procedure 1. Move the electrical harness to the left side in order to make room to install the transfer case shift control module. 2. Install the transfer case shift control module so that the electrical connector ports are to the right or pointing towards the instrument cluster. 3. While installing the transfer case shift control module rotate clockwise until the module is in place and the electrical connector ports are facing outwards. 4. Install the electrical harness retainer to the IP support beam. 5. Connect the 2 electrical connectors to the transfer case shift control module. 6. Install the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly the vehicle. 7. Connect all the electrical connectors to the lamp switch, cargo lamp and 4WD shift buttons assembly. 8. Install the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly in place. 9. Install the IP trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8252 10. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case NVG 149 ...................................................................................................................... ..................................................................................... 2.3L (2.4 Qt) NVG 236-246 ........................... .............................................................................................................................................................. ........... 1.9L (2.0 Qt) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 8257 Fluid - Transfer Case: Fluid Type Specifications Transfer Case NVG 149 .............................................................................................................................................. ..................... Auto-Trak II Fluid GM P/N 12378508 NVG 236/246 .......................................................................................................................................................... Auto-Trak II Fluid GM P/N 12378508 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) Fluid - Transfer Case: Service and Repair NVG 149-NP (One Speed Automatic) Transfer Case Fluid Replacement Removal Procedure Important: When performing the following service procedures, use only hand tools to remove and install the fill or drain plugs. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shields from the cross member (if equipped). 3. Remove the fill plug from the transfer case. Important: When draining the transfer case, make sure that an approved drain pan is used. 4. Remove the drain plug from the transfer case. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8260 Important: If the drain or fill plug have to be replaced, used only aluminum replacement drain plugs. 1. Install the drain plug in the transfer case. ^ Tighten the drain plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill hole with the proper fluid. 3. Install the fill plug. ^ Tighten the drain plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield to the cross member. 5. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8261 Fluid - Transfer Case: Service and Repair NVG 236/246-NP8 (Two Speed Automatic) Transfer Case Fluid Replacement Removal Procedure Important: When performing the following service procedures, use only hand tools in order to remove and install the fill or drain plugs. Always start the plugs by hand in order to prevent cross threading. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shields. 3. Remove the transfer case fill plug. 4. Remove the transfer case drain plug. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: If the drain or fill plug have to be replaced, used only aluminum replacement drain plugs. Steel plugs will react with the magnesium of Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8262 the transfer case. 1. Install the transfer case drain plug. ^ Tighten the transfer case drain plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill hole with the approved fluid. 3. Install the transfer case fill plug. ^ Tighten the transfer case fill plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield. 5. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 02-04-21-004 > Apr > 02 > Transfer Case Switch - `Service 4WD' Indicator ON Four Wheel Drive Selector Switch: Customer Interest Transfer Case Switch - `Service 4WD' Indicator ON File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-004 Date: April, 2002 TECHNICAL Subject: " "Service 4WD" Indicator Illuminated, DTC B2725 Set (Replace Transfer Case Shift Control Switch) Models: 1999-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Avalanche, Suburban, Tahoe, Yukon, Yukon XL) with Four Wheel Drive and NVG 236/246 Transfer Case (RPO NP8) Condition Some customers may comment on the Service 4WD indicator illuminating. Upon investigation, the technician may find DTC B2725 set. Cause The condition may be due to a intermittent fault in the transfer case shift control switch. Correction Important: The transfer case shift control module should not need replacement. DO NOT replace P/N 15749703 unless diagnosis points to the module as the malfunction. Replace the transfer case shift control switch using published Service Information procedures. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 02-04-21-004 > Apr > 02 > Transfer Case Switch - `Service 4WD' Indicator ON Four Wheel Drive Selector Switch: All Technical Service Bulletins Transfer Case Switch - `Service 4WD' Indicator ON File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-004 Date: April, 2002 TECHNICAL Subject: " "Service 4WD" Indicator Illuminated, DTC B2725 Set (Replace Transfer Case Shift Control Switch) Models: 1999-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Avalanche, Suburban, Tahoe, Yukon, Yukon XL) with Four Wheel Drive and NVG 236/246 Transfer Case (RPO NP8) Condition Some customers may comment on the Service 4WD indicator illuminating. Upon investigation, the technician may find DTC B2725 set. Cause The condition may be due to a intermittent fault in the transfer case shift control switch. Correction Important: The transfer case shift control module should not need replacement. DO NOT replace P/N 15749703 unless diagnosis points to the module as the malfunction. Replace the transfer case shift control switch using published Service Information procedures. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Transfer Case Shift Control Switch - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Transfer Case Shift Control Switch - C1 > Page 8278 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 8279 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel bezel trim piece. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. 1. Install the transfer case driver control switch into the instrument panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 8280 2. Install the instrument panel trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises Output Shaft: Customer Interest Driveline - Bump/Clunk/Squawking Noises Bulletin No.: 01-04-17-004B Date: January 05, 2005 TECHNICAL Subject: Clunk, Bump or Squawk when Vehicle Comes to Complete Stop or Accelerating from Complete Stop (Replace Rear Drive Shaft Nickel-Plated Slip Yoke) Models Supercede: This bulletin is being revised to add Cadillac Escalade (Old Style) to the Models section. Please discard Corporate Bulletin Number 01-04-17-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a clunk, bump or squawk noise when the vehicle comes to a stop or when accelerating from a complete stop. Cause A slip/stick condition between the transfer case output shaft and the driveshaft slip yoke may cause this condition. Diagnostic Tips There are several resources in the electronic Service Information System which can provide the technician with information on diagnosis and repair of clunk conditions, and fix the customer's vehicle right the first time without unnecessary parts replacement. Some of the documents available in SI include: ^ Symptoms - Propeller Shaft Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8289 ^ Knock or Clunk Noise ^ Rear Drive Axle Noises (SI Document ID #700580) ^ Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin # 02-04-17-001 ^ Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin # 01-07-30-042 ^ Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin # 03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case. Note: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 6. Support the propeller shaft in a line horizontal with the table of a press. Important: Remove the front slip yoke and the universal joint together. The new nickel-plated slip yoke comes with a new universal joint. 7. Disassemble the snap rings by pinching the ends together with a pair of pliers. 8. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 9. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8290 10. Place the J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 11. If you do not completely remove the bearing cup, lift the cross and insert the J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 12. Rotate the propeller shaft. Press the opposite bearing cup out of the drive shaft yoke. 13. Remove the old slip yoke and universal joint. 14. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 15. Inspect the bearing cup bores for burrs or imperfections. 16. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. 17. Install the new nickel-plated slip yoke and universal joint. See parts table below for parts information. 18. Remove the bearing cups from the universal joint. 19. Assemble one bearing cup part way into one side of the yoke. Turn the yoke ear toward the bottom. 20. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8291 21. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 22. Install the opposite bearing cup part way into the yoke ear. 23. Ensure that the trunnions start straight and true into both bearing cups. 24. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 25. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 26. Assemble the bearing retainer in the retainer groove. 27. Continue pressing until both retainers can be snapped into place. 28. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a soft-faced dead blow hammer. 29. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. 30. Install the slip yoke onto the output shaft in the transfer case. 31. Align the reference marks on the pinion flange and the propeller shaft. 32. Install the yoke retainers and bolts. Tighten Tighten the yoke retainer bolts to 25 N.m (19 lb ft). 33. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8292 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8293 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8294 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8295 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8296 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8297 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8298 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises Output Shaft: All Technical Service Bulletins Driveline - Bump/Clunk/Squawking Noises Bulletin No.: 01-04-17-004B Date: January 05, 2005 TECHNICAL Subject: Clunk, Bump or Squawk when Vehicle Comes to Complete Stop or Accelerating from Complete Stop (Replace Rear Drive Shaft Nickel-Plated Slip Yoke) Models Supercede: This bulletin is being revised to add Cadillac Escalade (Old Style) to the Models section. Please discard Corporate Bulletin Number 01-04-17-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a clunk, bump or squawk noise when the vehicle comes to a stop or when accelerating from a complete stop. Cause A slip/stick condition between the transfer case output shaft and the driveshaft slip yoke may cause this condition. Diagnostic Tips There are several resources in the electronic Service Information System which can provide the technician with information on diagnosis and repair of clunk conditions, and fix the customer's vehicle right the first time without unnecessary parts replacement. Some of the documents available in SI include: ^ Symptoms - Propeller Shaft Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8304 ^ Knock or Clunk Noise ^ Rear Drive Axle Noises (SI Document ID #700580) ^ Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin # 02-04-17-001 ^ Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin # 01-07-30-042 ^ Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin # 03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case. Note: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 6. Support the propeller shaft in a line horizontal with the table of a press. Important: Remove the front slip yoke and the universal joint together. The new nickel-plated slip yoke comes with a new universal joint. 7. Disassemble the snap rings by pinching the ends together with a pair of pliers. 8. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 9. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8305 10. Place the J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 11. If you do not completely remove the bearing cup, lift the cross and insert the J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 12. Rotate the propeller shaft. Press the opposite bearing cup out of the drive shaft yoke. 13. Remove the old slip yoke and universal joint. 14. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 15. Inspect the bearing cup bores for burrs or imperfections. 16. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. 17. Install the new nickel-plated slip yoke and universal joint. See parts table below for parts information. 18. Remove the bearing cups from the universal joint. 19. Assemble one bearing cup part way into one side of the yoke. Turn the yoke ear toward the bottom. 20. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8306 21. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 22. Install the opposite bearing cup part way into the yoke ear. 23. Ensure that the trunnions start straight and true into both bearing cups. 24. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 25. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 26. Assemble the bearing retainer in the retainer groove. 27. Continue pressing until both retainers can be snapped into place. 28. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a soft-faced dead blow hammer. 29. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. 30. Install the slip yoke onto the output shaft in the transfer case. 31. Align the reference marks on the pinion flange and the propeller shaft. 32. Install the yoke retainers and bolts. Tighten Tighten the yoke retainer bolts to 25 N.m (19 lb ft). 33. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8307 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8308 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8309 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8310 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8311 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8312 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8313 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 02-04-21-007 > Sep > 02 > Drivetrain - New Transfer Case Output Bearing Tool Output Shaft: All Technical Service Bulletins Drivetrain - New Transfer Case Output Bearing Tool File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-007 Date: September, 2002 INFORMATION Subject: Release of New Tool J 45380 - Rear Output Shaft Bushing Remover and Installer Models: 1998-2003 Light Duty Truck Models with AWD or 4WD and any of the following Transfer Case Models: 126, 136, 149, 226, 233, 236, 246, 261 or 263 (Except 261 SHD or 263 SHD) A new tool, J 45380, has been released to remove and install the rear output shaft bearing. The following procedures may be used. Identification Identify the transfer case model as shown in the figure shown. Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Information. 2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement in the Transfer Case sub-section of the Service Information. 3. Remove the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in the Propeller Shaft sub-section of the Service Information. 4. Remove the rear output shaft seal. 5. Inspect the rear output shaft bushing for scoring or wear. 6. Remove the rear output shaft bushing using the J 45380. 6.1. Install the finger section of the J 45380 in the front of the bushing. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 02-04-21-007 > Sep > 02 > Drivetrain - New Transfer Case Output Bearing Tool > Page 8318 6.2. Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. 6.3. Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Using the J 45380, install a NEW rear output shaft bushing. ^ Install the bushing on the finger section of the J 45380. ^ Install the finger section of the J 45380. ^ Position the bushing and the tool to the case. ^ Using a hammer and J 45380, install the bushing. 2. Using the appropriate seal installer, install the rear output shaft seal in the transfer case. 3. Install the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in the Propeller Shaft sub-section of the Service Information. 4. Verify the fluid level. Refer to Transfer Case Fluid Replacement. 5. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement in the Transfer Case sub-section of the Service Information. 6. Lower the vehicle. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Output Shaft: > 02-04-21-007 > Sep > 02 > Drivetrain - New Transfer Case Output Bearing Tool Output Shaft: All Technical Service Bulletins Drivetrain - New Transfer Case Output Bearing Tool File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-007 Date: September, 2002 INFORMATION Subject: Release of New Tool J 45380 - Rear Output Shaft Bushing Remover and Installer Models: 1998-2003 Light Duty Truck Models with AWD or 4WD and any of the following Transfer Case Models: 126, 136, 149, 226, 233, 236, 246, 261 or 263 (Except 261 SHD or 263 SHD) A new tool, J 45380, has been released to remove and install the rear output shaft bearing. The following procedures may be used. Identification Identify the transfer case model as shown in the figure shown. Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Information. 2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement in the Transfer Case sub-section of the Service Information. 3. Remove the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in the Propeller Shaft sub-section of the Service Information. 4. Remove the rear output shaft seal. 5. Inspect the rear output shaft bushing for scoring or wear. 6. Remove the rear output shaft bushing using the J 45380. 6.1. Install the finger section of the J 45380 in the front of the bushing. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Output Shaft: > 02-04-21-007 > Sep > 02 > Drivetrain - New Transfer Case Output Bearing Tool > Page 8324 6.2. Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. 6.3. Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Using the J 45380, install a NEW rear output shaft bushing. ^ Install the bushing on the finger section of the J 45380. ^ Install the finger section of the J 45380. ^ Position the bushing and the tool to the case. ^ Using a hammer and J 45380, install the bushing. 2. Using the appropriate seal installer, install the rear output shaft seal in the transfer case. 3. Install the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in the Propeller Shaft sub-section of the Service Information. 4. Verify the fluid level. Refer to Transfer Case Fluid Replacement. 5. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement in the Transfer Case sub-section of the Service Information. 6. Lower the vehicle. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 8330 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 Control Module: Diagrams Transfer Case Shift Control Module - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 > Page 8333 Transfer Case Shift Control Module - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 > Page 8334 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8335 Control Module: Service and Repair Transfer Case Shift Control Module Replacement Removal Procedure 1. Remove the IP trim bezel. 2. Pull out the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly in order to disconnect the electrical connectors. 3. Disconnect all the electrical connectors from the lamp switch, cargo lamp and 4WD shift buttons assembly. 4. Remove the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly from the vehicle. 5. Remove the electrical harness retainer from the IP support beam. 6. Disconnect the 2 electrical connectors from the transfer case shift control module. 7. Move the electrical harness to the left side in order to make room to turn the transfer case shift control module. 8. Rotate the transfer case shift control module about 45 degrees counter clockwise while pulling out at the same time until the module is Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8336 approximately 90 degrees from the original position. 9. Pull out the module from the vehicle. Installation Procedure 1. Move the electrical harness to the left side in order to make room to install the transfer case shift control module. 2. Install the transfer case shift control module so that the electrical connector ports are to the right or pointing towards the instrument cluster. 3. While installing the transfer case shift control module rotate clockwise until the module is in place and the electrical connector ports are facing outwards. 4. Install the electrical harness retainer to the IP support beam. 5. Connect the 2 electrical connectors to the transfer case shift control module. 6. Install the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly the vehicle. 7. Connect all the electrical connectors to the lamp switch, cargo lamp and 4WD shift buttons assembly. 8. Install the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly in place. 9. Install the IP trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8337 10. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NVG 149-NP (One Speed Automatic) Seals and Gaskets: Service and Repair NVG 149-NP (One Speed Automatic) Transfer Case Output Shaft Seal Replacement- Front Transfer Case Output Shaft Seal Replacement- Front ^ Tools Required J 8092 Universal Handle - J 43484 Front Output Shaft Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield from the crossmember (if equipped). 3. Remove the front propeller shaft from the vehicle. 4. Insert a Flat-tipped screwdriver in the inner race. 5. Pry the inner race back. 6. Insert a small pry bar in the inner race. Important: When performing the following service procedure, the outer part of the seal will slightly move out of the transfer case with the inner part seal. 7. Pry the inner part of the seal from the outer seal body. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8342 8. Remove the inner part of the seal. 9. Insert a flat-tipped screwdriver or small pry bar in the space between the outer race of the seal and the transfer easier. 10. Pry the outer race out of the transfer case. 11. Remove the outer part of the seal. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8343 1. Install the J 43484 (2) to the J 8092 (1). 2. Install the transfer case front input shaft on the J 43484. 3. Using the J 43484 (2) and the J 8092 (1), install the transfer case output seal. 4. Install the front propeller shaft. 5. Check the transfer case fluid level. 6. Install the transfer case shield. 7. Lower the vehicle. Refer to Vehicle Lifting. Transfer Case Output Shaft Seal Replacement- Rear Transfer Case Output Shaft Seal Replacement- Rear ^ Tools Required J 37668-A Seal Installer - J 45380 Transfer Case Rear Bushing Remover and Installer Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the rear propeller shaft. 4. Remove the rear output shaft seal. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8344 5. Inspect the rear output shaft bushing for scoring or wear. 6. Remove the rear output shaft bushing if required, using the J 45380. ^ Install the finger section of the J 45380 in front of the bushing. ^ Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. ^ Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Using the J 45380, install a NEW rear output shaft bushing. ^ Install the bushing or the finger section of the J 45380. ^ Install the finger section of the J 45380. ^ Position the bushing and tool to the case. ^ Using a hammer and J 45380, install the bushing. Important: Ensure the drain hole on the boot of the rear output shaft seal is facing down toward the ground. 2. Using the J 37668-A, install the front output shaft in the transfer case. 3. Install the rear propeller shaft. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8345 4. Check the fluid level. 5. Install the transfer case shield. 6. Lower the vehicle. Transfer Case Input Shaft Seal Replacement Transfer Case Input Shaft Seal Replacement ^ Tools Required J 42733 Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case from the adapter. 3. Remove the input shaft seal from the transfer case. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8346 Important: When installing the input shaft seal, make sure that the part numbers on the seal are facing outward (toward the technician). The input shaft seal should be even with the surface of the transfer case after installation. 1. Position the seal on the input shaft. 2. Using the J42738, install the input shaft seal in the transfer case. 3. Install the transfer case to the adapter. 4. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8347 Seals and Gaskets: Service and Repair NVG 236/246-NP8 (Two Speed Automatic) Transfer Case Output Shaft Seal Replacement- Front Transfer Case Output Shaft Seal Replacement- Front ^ Tools Required J 8092 Universal Handle - J 43484 Front Output Shaft Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield from the crossmember (if equipped). 3. Remove the front propeller shaft from the vehicle. 4. Insert a flat-tipped screwdriver in the inner race. 5. Pry the inner race back. 6. Insert a small pry bar in the inner race. Important: When performing the following service procedure, the outer part of the seal will slightly move out of the transfer case with the inner part seal. 7. Pry the inner part of the seal from the outer seal body. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8348 8. Remove the inner part of the seal. 9. Insert a flat-tipped screwdriver or small pry bar in the space between the outer race of the seal and the transfer case. 10. Pry the outer race out of the transfer case. 11. Remove the outer part of the seal. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8349 1. Install the J 43484 (2) to the J 8092 (1). 2. Install the transfer case front input shaft seal on the J 43484. 3. Using the J 43484 (2) and the J 8092 (1), install the transfer case output seal. 4. Install the front propeller shaft. 5. Check the transfer case fluid level. 6. Install the transfer case shield. 7. Lower the vehicle. Refer to Vehicle Lifting. Transfer Case Output Shaft Seal Replacement- Rear Transfer Case Output Shaft Seal Replacement- Rear ^ Tools Required J 37668-A Seal Installer - J 45380 Transfer Case Rear Bushing Remover and Installer Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield. 3. Remove the rear propeller shaft. 4. Remove the rear output shaft seal from the transfer case. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8350 5. Inspect the rear output shaft bushing for scoring or wear. 6. Remove the rear output shaft bushing if required, using the J 45380. ^ Install the finger section of the J 45380 in front of the bushing. ^ Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. ^ Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Using the J 37668-A, install a NEW rear output shaft bushing. ^ Install the bushing or the finger section of the J 37668-A. ^ Install the finger section to the main body of the J 37668-A. ^ Position the bushing and tool to the case. ^ Using a hammer and J 37668-A, install the bushing. Important: When installing the rear output shaft seal to the transfer case, ensure that the locator tab is facing up. 2. Position the rear output shaft seal in the transfer case. 3. Using the J 37668-A, install the rear output shaft to the transfer case. 4. Install the rear propeller shaft. 5. Inspect the transfer case fluid level. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8351 6. Install the transfer case shield. 7. Lower the vehicle. Transfer Case Input Shaft Seal Replacement Transfer Case Input Shaft Seal Replacement ^ Tools Required J 42738 Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case assembly. 3. Remove the transfer case input shaft seal. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8352 Important: When installing the input shaft seal, make sure that the part numbers on the seal are facing outward (away from the body of the transfer case). 1. Align the transfer case input shaft seal evenly on the input shaft. Important: The input shaft seal should be even with the surface of the transfer case after installation. 2. Using the J 42738, install the transfer case input shaft seal. 3. Install the transfer case assembly in the vehicle. 4. Check the transfer case fluid level. 5. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 02-04-21-004 > Apr > 02 > Transfer Case Switch - `Service 4WD' Indicator ON Four Wheel Drive Selector Switch: Customer Interest Transfer Case Switch - `Service 4WD' Indicator ON File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-004 Date: April, 2002 TECHNICAL Subject: " "Service 4WD" Indicator Illuminated, DTC B2725 Set (Replace Transfer Case Shift Control Switch) Models: 1999-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Avalanche, Suburban, Tahoe, Yukon, Yukon XL) with Four Wheel Drive and NVG 236/246 Transfer Case (RPO NP8) Condition Some customers may comment on the Service 4WD indicator illuminating. Upon investigation, the technician may find DTC B2725 set. Cause The condition may be due to a intermittent fault in the transfer case shift control switch. Correction Important: The transfer case shift control module should not need replacement. DO NOT replace P/N 15749703 unless diagnosis points to the module as the malfunction. Replace the transfer case shift control switch using published Service Information procedures. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 02-04-21-004 > Apr > 02 > Transfer Case Switch - `Service 4WD' Indicator ON Four Wheel Drive Selector Switch: All Technical Service Bulletins Transfer Case Switch - `Service 4WD' Indicator ON File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-004 Date: April, 2002 TECHNICAL Subject: " "Service 4WD" Indicator Illuminated, DTC B2725 Set (Replace Transfer Case Shift Control Switch) Models: 1999-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Avalanche, Suburban, Tahoe, Yukon, Yukon XL) with Four Wheel Drive and NVG 236/246 Transfer Case (RPO NP8) Condition Some customers may comment on the Service 4WD indicator illuminating. Upon investigation, the technician may find DTC B2725 set. Cause The condition may be due to a intermittent fault in the transfer case shift control switch. Correction Important: The transfer case shift control module should not need replacement. DO NOT replace P/N 15749703 unless diagnosis points to the module as the malfunction. Replace the transfer case shift control switch using published Service Information procedures. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Transfer Case Shift Control Switch - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Transfer Case Shift Control Switch - C1 > Page 8369 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 8370 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel bezel trim piece. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. 1. Install the transfer case driver control switch into the instrument panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 8371 2. Install the instrument panel trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Page 8376 Speed Sensor: Specifications Transfer Case Speed Sensors ............................................................................................................ ........................................................ 15 Nm (11 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 8379 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) Speed Sensor: Service and Repair NVG 149-NP (One Speed Automatic) Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the electrical connector from the speed sensor. 3. Remove the speed sensor from the transfer case. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8382 1. Install the right rear speed sensor into the transfer case. ^ Tighten the right rear speed sensor to 31 Nm (23 ft. lbs.). 2. Install the electrical connector to the speed sensor. 3. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8383 Speed Sensor: Service and Repair NVG 236/246-NP8 (Two Speed Automatic) Transfer Case Speed Sensor Replacement (Front) Transfer Case Speed Sensor Replacement (Front) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield. 3. Remove the transfer case front speed sensor electrical connector. 4. Remove the transfer case front speed sensor. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8384 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case front speed sensor into the transfer case. ^ Tighten the transfer case front speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case front speed sensor electrical connector. 3. Install the transfer case shield. 4. Lower the vehicle. Refer to Vehicle Lifting. Transfer Case Speed Sensor Replacement (Right Rear) Transfer Case Speed Sensor Replacement (Right Rear) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8385 2. Remove the transfer case right rear electrical connector. 3. Remove the transfer case right rear speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case right rear speed sensor to the transfer case. ^ Tighten the transfer case right rear speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case right rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Transfer Case Speed Sensor Replacement (Left Rear) Transfer Case Speed Sensor Replacement (Left Rear) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case left rear speed sensor electrical connector. 3. Remove the transfer case left rear speed sensor. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8386 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case left rear speed sensor into the transfer case. ^ Tighten the transfer case left rear speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case left rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Page 8391 Speed Sensor: Specifications Transfer Case Speed Sensors ............................................................................................................ ........................................................ 15 Nm (11 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 8394 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) Speed Sensor: Service and Repair NVG 149-NP (One Speed Automatic) Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the electrical connector from the speed sensor. 3. Remove the speed sensor from the transfer case. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8397 1. Install the right rear speed sensor into the transfer case. ^ Tighten the right rear speed sensor to 31 Nm (23 ft. lbs.). 2. Install the electrical connector to the speed sensor. 3. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8398 Speed Sensor: Service and Repair NVG 236/246-NP8 (Two Speed Automatic) Transfer Case Speed Sensor Replacement (Front) Transfer Case Speed Sensor Replacement (Front) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield. 3. Remove the transfer case front speed sensor electrical connector. 4. Remove the transfer case front speed sensor. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8399 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case front speed sensor into the transfer case. ^ Tighten the transfer case front speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case front speed sensor electrical connector. 3. Install the transfer case shield. 4. Lower the vehicle. Refer to Vehicle Lifting. Transfer Case Speed Sensor Replacement (Right Rear) Transfer Case Speed Sensor Replacement (Right Rear) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8400 2. Remove the transfer case right rear electrical connector. 3. Remove the transfer case right rear speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case right rear speed sensor to the transfer case. ^ Tighten the transfer case right rear speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case right rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Transfer Case Speed Sensor Replacement (Left Rear) Transfer Case Speed Sensor Replacement (Left Rear) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case left rear speed sensor electrical connector. 3. Remove the transfer case left rear speed sensor. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8401 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case left rear speed sensor into the transfer case. ^ Tighten the transfer case left rear speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case left rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications NVG 149-NP (One Speed Automatic) Transfer Case Motor/Encoder Bolts ..................................................................................................................................................... 20 Nm (14 ft. lbs.) NVG 236/246-NP8 (Two Speed Automatic) Transfer Case Motor/Encoder Bolts ..................................................................................................................................................... 20 Nm (15 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Front Axle Actuator Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Front Axle Actuator > Page 8407 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Front Axle Actuator > Page 8408 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8409 Transfer Case Actuator: Service and Repair Transfer Case Motor/Encoder Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield. 3. Remove the front propeller shaft. 4. Remove the motor/encoder electrical connectors. 5. Remove the motor/encoder mounting bolts. 6. Remove the motor/encoder assembly. 7. Remove the motor/encoder gasket. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8410 Important: ^ If the motor/encoder assembly is being replaced because it is defective, make sure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench if necessary. ^ When installing the motor/encoder unit to the transfer case, make sure that the transfer case is indexed properly and it is flat against the transfer case before tightening the mounting bolts. 1. Install the NEW motor/encoder gasket to the transfer case. 2. Install the motor/encoder to the transfer case. Notice: Refer to Fastener Notice in Service Precautions. 3. Install motor/encoder mounting bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 4. Install the motor/encoder electrical connector. Ensure that the retention clips activate. 5. Install the front propeller shaft. 6. Install the transfer case shield. 7. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Clutch > Component Information > Technical Service Bulletins > Transfer Case - 1st & 2nd Clutch Hub & Apply Plate Transfer Case Clutch: Technical Service Bulletins Transfer Case - 1st & 2nd Clutch Hub & Apply Plate Bulletin No.: 05-04-21-005 Date: August 03, 2005 INFORMATION Subject: First and Second Design Clutch Hub and Apply Plate for NV246 Transfer Case Models: 1999-2004 Chevrolet Full Size Pickups and Utilities 1999-2004 GMC Full Size Pickups and Utilities with NV246 Transfer Case (RPO NP8) If service requires replacement of the first design Clutch Hub (17) that is no longer available form GMSPO ,the second design Clutch Hub (17) requires a second design Apply Plate (18) also be replaced in order to obtain proper stack up height in the transfer case. ^ 1999-2002 vehicles that require replacement of the Clutch Hub (17), P/N 88962324 second design also require the Apply Plate (18), P/N 88962331 second design to be replaced at the same time in order to obtain proper stack up height in the transfer case. ^ 2003-2004 vehicles that require replacement of the Clutch Hub (17), P/N 88962324 second design also require the Apply Plate (18), P/N 88962327 second design to be replaced at the same time in order to obtaining proper stack up height in the transfer case. Important: ^ A clutch plate shim package is necessary in order to have the proper shims available for setting the correct clutch pack preload. Improper preload may cause driveability concerns and failure of the transfer case. ^ Transfer case shims are available from GMSPO. Refer to Corporate Bulletin Number 04-04-21-003. ^ Whenever the second design Clutch Hub and the second design Apply Plate are used, a revised stack height will have to be used. This implements a shim J-44295-4 (0.085 in. thick) in conjunction with the clutch pack shimming kit J-44295 to achieve the correct stack height. Refer to SI Unit Repair, Transfer Case Assemble. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Clutch > Component Information > Technical Service Bulletins > Transfer Case - 1st & 2nd Clutch Hub & Apply Plate > Page 8415 Transfer Case Clutch: Technical Service Bulletins Drivetrain - Transfer Case Clutch Shimming Bulletin No.: 04-04-21-003 Date: November 10, 2004 INFORMATION Subject: Automatic Transfer Case Clutch Plate Shimming - Parts Availability Change Models: 1999-2000 Cadillac Escalade 1998-2005 Chevrolet Blazer 1999-2005 Chevrolet Astro Van, Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1998-2005 GMC Jimmy 1999 GMC Suburban 1999-2005 GMC Safari Van, Sierra, Yukon, Yukon XL 1998-2001 Oldsmobile Bravada with NV 136/236/246 Automatic Transfer Case (RPO NP4 or NP8) While performing the transfer case clutch shimming procedure found in Service Information (SI), you may find it necessary to replace the clutch pack selective fit shim to obtain the correct clutch pack clearance. The selective fit shims for this repair were previously released as a kit, P/N 12474121, which contained all eight selective fit sizes. Effective immediately, the clutch pack shims will be available individually as listed below. The shim kit, P/N 12474121, will be discontinued and no longer available once current stock has been depleted. Parts Information Parts are currently available from GMSPO. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Mount > Component Information > Specifications Transfer Case Mount: Specifications NVG 149-NP (One Speed Automatic) Transmission Mount to Crossmember Nuts .......................................................................................................................................... 40 Nm (29 ft. lbs.) Transmission Mount to Transfer Case Adapter Bolts ........................................................................................................................... 47 Nm (34 ft. lbs.) NVG 236/246-NP8 (Two Speed Automatic) Transmission Mount to Crossmember Nuts .......................................................................................................................................... 40 Nm (29 ft. lbs.) Transmission Mount to Transfer Case Adapter Bolts ........................................................................................................................... 47 Nm (34 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications Pressure Regulating Solenoid: Specifications 4L60-E Pressure Control Solenoid Bracket to Valve Body Bolt ....................................................................... .......................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) 4L80-E Pressure Control Solenoid Bracket to Valve Body .............................................................................. ...................................................................................................................... 8 Nm (71 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > 4L60-E > Page 8427 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E Pressure Regulating Solenoid: Service and Repair 4L60-E Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 8430 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 8431 Pressure Regulating Solenoid: Service and Repair 4L80-E Pressure Regulator Replacement ^ Tools Required J 36850 Transjel Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 3. Remove the reverse boost valve bushing retainer ring (2). 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 8432 1. Install the pressure regulator valve with J 36850. 2. Pre-assemble the following parts: ^ The reverse boost valve bushing ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission oil pan and the oil filter. 6. Lower the vehicle. 7. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 8436 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the body control module bracket. 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator away from the steering column jacket assembly and the cable shift cam assembly. 6. Remove the automatic transmission shift lock control actuator. Installation Procedure 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket assembly and the cable shift cam assembly. 2. Connect the electrical connector 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 8437 3.1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. 3.2. Press on the adjuster block (2) to compress the internal adjuster spring, which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 4.1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 4.2. Depress the brake pedal to move the shift lever out of the park position. 4.3. The actuator will be energized. 4.4. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the body control module bracket. 6. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications 4L80-E Solenoid to Valve Body ....................................................................................................................... ............................................... 8 Nm (71 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E Shift Solenoid: Diagrams 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 4L60-E > Page 8443 Shift Solenoid: Diagrams 4L80-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 8444 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 8445 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 8446 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 8447 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications 4L60-E TCC Solenoid Assembly to Case Bolt ..................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E Torque Converter Clutch Solenoid: Diagrams 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 4L60-E > Page 8453 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E Torque Converter Clutch Solenoid: Service and Repair 4L60-E Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 8456 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts, which retain the internal wiring harness. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 8457 11. Using J28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 8458 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts, which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 8459 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Refer to Transmission Fluid Checking Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 8460 Torque Converter Clutch Solenoid: Service and Repair 4L80-E Torque Converter Clutch (TCC) Valve and Spring Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the oil filter. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 3. Remove the valve bore plug retainer ring (1). 4. Remove the following parts: ^ The valve bore plug ^ The TCC valve ^ The TCC valve spring Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 4L60-E > Page 8461 1. Install the following parts: ^ The TCC valve spring ^ The TCC valve ^ The valve bore plug 2. Install the valve bore plug retainer ring (1). 3. Install the transmission oil pan and oil filter. 4. Lower the vehicle. 5. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications NVG 149-NP (One Speed Automatic) Transfer Case Motor/Encoder Bolts ..................................................................................................................................................... 20 Nm (14 ft. lbs.) NVG 236/246-NP8 (Two Speed Automatic) Transfer Case Motor/Encoder Bolts ..................................................................................................................................................... 20 Nm (15 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Front Axle Actuator Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Front Axle Actuator > Page 8468 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Front Axle Actuator > Page 8469 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8470 Transfer Case Actuator: Service and Repair Transfer Case Motor/Encoder Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield. 3. Remove the front propeller shaft. 4. Remove the motor/encoder electrical connectors. 5. Remove the motor/encoder mounting bolts. 6. Remove the motor/encoder assembly. 7. Remove the motor/encoder gasket. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8471 Important: ^ If the motor/encoder assembly is being replaced because it is defective, make sure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench if necessary. ^ When installing the motor/encoder unit to the transfer case, make sure that the transfer case is indexed properly and it is flat against the transfer case before tightening the mounting bolts. 1. Install the NEW motor/encoder gasket to the transfer case. 2. Install the motor/encoder to the transfer case. Notice: Refer to Fastener Notice in Service Precautions. 3. Install motor/encoder mounting bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 4. Install the motor/encoder electrical connector. Ensure that the retention clips activate. 5. Install the front propeller shaft. 6. Install the transfer case shield. 7. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation The IPC displays the vehicle speed based on the vehicle speed signal from the PCM. The PCM converts the data from the vehicle speed sensor to a 4000 pulses/mile signal. The IPC uses the vehicle speed signal circuit from the PCM in order to calculate the vehicle speed. The speedometer defaults to 0 km/h (0 mph) if a malfunction in the vehicle speed signal circuit exists. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 8483 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 Control Module: Diagrams Transfer Case Shift Control Module - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 > Page 8486 Transfer Case Shift Control Module - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module - C1 > Page 8487 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8488 Control Module: Service and Repair Transfer Case Shift Control Module Replacement Removal Procedure 1. Remove the IP trim bezel. 2. Pull out the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly in order to disconnect the electrical connectors. 3. Disconnect all the electrical connectors from the lamp switch, cargo lamp and 4WD shift buttons assembly. 4. Remove the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly from the vehicle. 5. Remove the electrical harness retainer from the IP support beam. 6. Disconnect the 2 electrical connectors from the transfer case shift control module. 7. Move the electrical harness to the left side in order to make room to turn the transfer case shift control module. 8. Rotate the transfer case shift control module about 45 degrees counter clockwise while pulling out at the same time until the module is Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8489 approximately 90 degrees from the original position. 9. Pull out the module from the vehicle. Installation Procedure 1. Move the electrical harness to the left side in order to make room to install the transfer case shift control module. 2. Install the transfer case shift control module so that the electrical connector ports are to the right or pointing towards the instrument cluster. 3. While installing the transfer case shift control module rotate clockwise until the module is in place and the electrical connector ports are facing outwards. 4. Install the electrical harness retainer to the IP support beam. 5. Connect the 2 electrical connectors to the transfer case shift control module. 6. Install the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly the vehicle. 7. Connect all the electrical connectors to the lamp switch, cargo lamp and 4WD shift buttons assembly. 8. Install the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly in place. 9. Install the IP trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8490 10. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications 4L60-E Transmission Fluid Pressure Manual Valve Position Switch to Valve ................................................. ................................................................................................................................... 8.0-14.0 Nm (6-10 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E A/T Fluid Pressure Manual Valve Position Switch Connector, Wiring Harness Side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > 4L60-E > Page 8498 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 8499 Fluid Pressure Sensor/Switch: Service and Repair For information relating to service of this component please refer to Valve Body; Service And Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Transmission Mode Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 8504 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 8505 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for voltage through the body wiring harness junction block. 7. This step tests for ground integrity at the splice pack. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 8506 Transmission Mode Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 8507 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 8508 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for voltage through the body wiring harness junction block. 7. This step tests for ground integrity at the splice pack. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 4L60-E Park/Neutral Position Switch Screw .................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E > Page 8514 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E Transmission Position Switch/Sensor: Adjustments 4L60-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E > Page 8517 Transmission Position Switch/Sensor: Adjustments 4L80-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E Transmission Position Switch/Sensor: Service and Repair 4L60-E Park Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 8520 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 8521 Transmission Position Switch/Sensor: Service and Repair 4L80-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 8522 4. Position the tool J41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications 4L60-E Speed Sensor Retainer Bolt ................................................................................................................................................. 10.5-13.5 Nm (7.7-10 ft. lbs.) 4L80-E Speed Sensor and Bracket Assembly to Case .................................................................................................................................... 11 Nm (97 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E Vehicle Speed Sensor (VSS) Sensor Connector, Wiring Harness Side (4L60-E) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4L60-E > Page 8528 Transmission Speed Sensor: Diagrams 4L80-E Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E Transmission Speed Sensor: Service and Repair 4L60-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 8531 Transmission Speed Sensor: Service and Repair 4L80-E Vehicle Speed Sensor (VSS) Replacement- Input Vehicle Speed Sensor (VSS) Replacement- Input Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor (1) electrical connector. 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1) and the bracket assembly from the case. 5. Inspect the vehicle speed sensor assembly (1) for any evidence of damage. Installation Procedure. 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1) and the bracket assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector. 5. Lower the vehicle. Vehicle Speed Sensor (VSS) Replacement-Output Vehicle Speed Sensor (VSS) Replacement-Output Removal Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 4L60-E > Page 8532 1. Raise the vehicle. Refer to Vehicle Lifting. Important: This procedure is for 2WD vehicles. If the vehicle is equipped with 4WD, the output speed sensor is located on the transfer case. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2) and the bracket assembly from the case. 5. Inspect the output speed sensor assembly (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2) and the bracket assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the output speed sensor electrical connector. 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Transmission Fluid Temperature (TFT) Sensor Connector, Wiring Harness Side (4L80-E) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 02-04-21-004 > Apr > 02 > Transfer Case Switch - `Service 4WD' Indicator ON Four Wheel Drive Selector Switch: Customer Interest Transfer Case Switch - `Service 4WD' Indicator ON File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-004 Date: April, 2002 TECHNICAL Subject: " "Service 4WD" Indicator Illuminated, DTC B2725 Set (Replace Transfer Case Shift Control Switch) Models: 1999-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Avalanche, Suburban, Tahoe, Yukon, Yukon XL) with Four Wheel Drive and NVG 236/246 Transfer Case (RPO NP8) Condition Some customers may comment on the Service 4WD indicator illuminating. Upon investigation, the technician may find DTC B2725 set. Cause The condition may be due to a intermittent fault in the transfer case shift control switch. Correction Important: The transfer case shift control module should not need replacement. DO NOT replace P/N 15749703 unless diagnosis points to the module as the malfunction. Replace the transfer case shift control switch using published Service Information procedures. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 02-04-21-004 > Apr > 02 > Transfer Case Switch - `Service 4WD' Indicator ON Four Wheel Drive Selector Switch: All Technical Service Bulletins Transfer Case Switch - `Service 4WD' Indicator ON File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-004 Date: April, 2002 TECHNICAL Subject: " "Service 4WD" Indicator Illuminated, DTC B2725 Set (Replace Transfer Case Shift Control Switch) Models: 1999-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Avalanche, Suburban, Tahoe, Yukon, Yukon XL) with Four Wheel Drive and NVG 236/246 Transfer Case (RPO NP8) Condition Some customers may comment on the Service 4WD indicator illuminating. Upon investigation, the technician may find DTC B2725 set. Cause The condition may be due to a intermittent fault in the transfer case shift control switch. Correction Important: The transfer case shift control module should not need replacement. DO NOT replace P/N 15749703 unless diagnosis points to the module as the malfunction. Replace the transfer case shift control switch using published Service Information procedures. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Transfer Case Shift Control Switch - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Transfer Case Shift Control Switch - C1 > Page 8552 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 8553 Four Wheel Drive Selector Switch: Service and Repair Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel bezel trim piece. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. 1. Install the transfer case driver control switch into the instrument panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 8554 2. Install the instrument panel trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Page 8559 Speed Sensor: Specifications Transfer Case Speed Sensors ............................................................................................................ ........................................................ 15 Nm (11 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 8562 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) Speed Sensor: Service and Repair NVG 149-NP (One Speed Automatic) Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the electrical connector from the speed sensor. 3. Remove the speed sensor from the transfer case. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8565 1. Install the right rear speed sensor into the transfer case. ^ Tighten the right rear speed sensor to 31 Nm (23 ft. lbs.). 2. Install the electrical connector to the speed sensor. 3. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8566 Speed Sensor: Service and Repair NVG 236/246-NP8 (Two Speed Automatic) Transfer Case Speed Sensor Replacement (Front) Transfer Case Speed Sensor Replacement (Front) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield. 3. Remove the transfer case front speed sensor electrical connector. 4. Remove the transfer case front speed sensor. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8567 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case front speed sensor into the transfer case. ^ Tighten the transfer case front speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case front speed sensor electrical connector. 3. Install the transfer case shield. 4. Lower the vehicle. Refer to Vehicle Lifting. Transfer Case Speed Sensor Replacement (Right Rear) Transfer Case Speed Sensor Replacement (Right Rear) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8568 2. Remove the transfer case right rear electrical connector. 3. Remove the transfer case right rear speed sensor. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case right rear speed sensor to the transfer case. ^ Tighten the transfer case right rear speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case right rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Transfer Case Speed Sensor Replacement (Left Rear) Transfer Case Speed Sensor Replacement (Left Rear) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case left rear speed sensor electrical connector. 3. Remove the transfer case left rear speed sensor. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > NVG 149-NP (One Speed Automatic) > Page 8569 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the transfer case left rear speed sensor into the transfer case. ^ Tighten the transfer case left rear speed sensor to 15 Nm (11 ft. lbs.). 2. Install the transfer case left rear speed sensor electrical connector. 3. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 8580 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 8586 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 02-04-21-004 > Apr > 02 > Transfer Case Switch - `Service 4WD' Indicator ON Four Wheel Drive Selector Switch: All Technical Service Bulletins Transfer Case Switch - `Service 4WD' Indicator ON File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-004 Date: April, 2002 TECHNICAL Subject: " "Service 4WD" Indicator Illuminated, DTC B2725 Set (Replace Transfer Case Shift Control Switch) Models: 1999-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Avalanche, Suburban, Tahoe, Yukon, Yukon XL) with Four Wheel Drive and NVG 236/246 Transfer Case (RPO NP8) Condition Some customers may comment on the Service 4WD indicator illuminating. Upon investigation, the technician may find DTC B2725 set. Cause The condition may be due to a intermittent fault in the transfer case shift control switch. Correction Important: The transfer case shift control module should not need replacement. DO NOT replace P/N 15749703 unless diagnosis points to the module as the malfunction. Replace the transfer case shift control switch using published Service Information procedures. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 8597 Electronic Brake Control Module: Specifications EBCM to BPMV Torx Bolts .................................................................................................................. ................................................. 5 Nm (39 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 8598 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 8601 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 8602 Electronic Brake Control Module: Diagrams C2 - W/O VSES Electronic Brake Control Module (EBCM) - C2 - w/o VSES Part 1 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 8603 Part 2 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 8604 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 8605 Electronic Brake Control Module: Diagrams C2 - W/O VSES Electronic Brake Control Module (EBCM) - C2 - w/o VSES Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 8606 Part 1 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 8607 Part 2 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 8608 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 8609 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module (EBCM) Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Electronic Brake Control Module (EBCM) Replacement (w/o JL4) Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. 3. Thoroughly wash all contaminants from around the EHCU (1). 4. Disconnect the electrical connectors from the EBCM. 5. Loosen or remove 3 bolts (4) securing the EHCU mounting bracket (3) to the frame rail (5). 6. Gently move the EHCU down enough to remove the four mounting screws that fasten the EBCM(2) to the BPMV(1). 7. Remove the EBCM (2) from the BPMV (1). Removal may require a light amount of force. 8. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module (EBCM) > Page 8612 1. Install the EBCM (2) on to the BPMV(1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four new screws in the EBCM (2). Tighten the four screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Install or tighten three EHCU bracket mounting bolts. Tighten the EHCU bracket mounting bolts to 25 Nm (18 ft. lbs.). 4. Connect the electrical connectors to the EBCM. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 8. Return to Diagnostic Starting Point - Antilock Brake System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module (EBCM) > Page 8613 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) (W/JL4) Electronic Brake Control Module (EBCM) Replacement (w/ JL4) Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. 3. Thoroughly wash all contaminants from around the EHCU (1). 4. Disconnect the brake fluid pressure sensor (7) and pressure accumulator switch (4) electrical connectors. 5. Remove the four mounting screws that fasten the EBCM (2) to the BPMV (1). 6. Remove the EBCM (2) from the BPMV (1). Removal may require a light amount of force. Important: Note the routing of the jumper harnesses for reinstallation. 7. Remove the EBCM and jumper harnesses from the vehicle. 8. Remove the jumper harnesses from the EBCM 9. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure 1. Install the jumper harnesses to the EBCM. 2. Install the EBCM and jumper harnesses to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module (EBCM) > Page 8614 Important: ^ Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. ^ Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 3. Install the EBCM (2) on to the BPMV (1). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the four new screws in the EBCM (2). Tighten the four screws to 5 Nm (39 inch lbs.) in an X-pattern. 5. Connect the brake fluid pressure sensor (7) and pressure accumulator switch (4) electrical connectors. 6. Lower the vehicle. 7. Connect the negative battery cable. 8. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 9. Return to Diagnostic Starting Point - Antilock Brake System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake Pressure Modulator Bleeder Valves ............................................................................................................................................. 9 Nm (80 inch lbs.) EHCU Bracket to Frame Bolt ............................................................................................... .................................................................... 25 Nm (18 ft. lbs.) EHCU to Bracket Allen Bolt .............. .......................................................................................................................................................... 9 Nm (7 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > W/ JL4 Hydraulic Control Assembly - Antilock Brakes: Service and Repair W/ JL4 Brake Pressure Modulator Valve (BPMV) Replacement (w/ JL4) Removal Procedure Important: The area around the Electric Hydraulic Control Unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled ABS components. 1. Thoroughly wash all contaminants from around the EHCU. 2. Disconnect the 2 electrical harness connectors from the Electronic Brake Control Module (EBCM) (1). 3. Disconnect the electrical connector from the pressure accumulator switch. 4. Disconnect the electrical connector from the brake fluid pressure sensor. Important: Make sure that brake lines are tagged and kept in order for proper reassembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > W/ JL4 > Page 8620 5. Disconnect the brake lines from the Brake Pressure Modulator Valve (BPMV) (2). 6. Remove the bolts (4) securing the EHCU mounting bracket (3) to the frame rail (5). 7. Remove the EHCU from the vehicle. 8. Remove the bolts (4) securing the BPMV (1) to the EHCU mounting bracket (3). 9. Remove the 4 T-25 torx bolts from the EBCM (2). 10. Remove the EBCM (2) from the BPMV (1). Removal may require a light amount of force. 11. Remove the accumulator switch. 12. Remove the brake fluid sensor (2). Important: Do not reuse the EBCM mounting bolts. Always install new bolts. 13. Clean the EBCM to BPMV mounting surfaces with a clean cloth. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > W/ JL4 > Page 8621 Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the pressure accumulator switch to the BPMV. Tighten the switch to 3 Nm (30 inch lbs.). 2. Install the brake fluid pressure sensor (2) using a backup wrench to keep the brake fluid pressure sensor collar (1) from turning. Tighten the sensor to 16 Nm (12 ft. lbs.). Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 3. Install the EBCM (2) onto BPMV (1). 4. Install the four EBCM bolts. Important: Do not reuse the old mounting bolts. Always install new EBCM bolts with the new BPMV. Tighten the bolts to 5 Nm (39 inch lbs.) in an X-pattern. 5. Connect the brake fluid pressure sensor and pressure accumulator switch electrical harnesses. 6. Install the BPMV (1) to EHCU bracket (3). 7. Install the BPMV to bracket retaining bolts (4). Tighten the bolts to 9 Nm (7 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > W/ JL4 > Page 8622 8. Install the EHCU to the vehicle frame (5). 9. Install the EHCU bracket bolts. Tighten the EHCU bracket bolts (4) to 25 Nm (18 ft. lbs.). 10. Connect the 2 electrical harness connectors to the EBCM (1). Important: The brake pipes are held in place by a plastic bracket mounted to the frame. Make sure that the brake pipes stay in the correct place for proper reassembly. 11. Install the brake pipes to the BPMV (2). Tighten the brake pipe fittings to 25 Nm (18 ft. lbs.). 12. Bleed the brake system. 13. Bleed the brake system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > W/ JL4 > Page 8623 Hydraulic Control Assembly - Antilock Brakes: Service and Repair W/O JL4 Brake Pressure Modulator Valve (BPMV) Replacement (w/o JL4) Removal Procedure Important: The area around the electric hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled ABS components. 1. Thoroughly wash all contaminants from around the EHCU. 2. Disconnect the 3 electrical harness connectors from the electronic brake control module (EBCM) (1). Important: Make sure that brake lines are tagged and kept in order for proper reassembly. 3. Disconnect the brake lines from the brake pressure modulator valve (BPMV) (2). 4. Remove the bolts (4) securing the EHCU mounting bracket (3) to the frame rail (5). 5. Remove the EHCU from the vehicle. 6. Remove the bolts (4) securing the BPMV (1) to the EHCU mounting bracket (3). 7. Disconnect the 2 way ABS pump motor connector. 8. Remove the 4 T-25 TORX bolts from the EBCM (2). 9. Remove the EBCM (2) from the BPMV (1). Removal may require a light amount of force. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. 10. Clean the EBCM to BPMV mounting surfaces with a clean cloth. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > W/ JL4 > Page 8624 Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install the EBCM (2) onto BPMV (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four EBCM bolts. Important: Do not reuse the old mounting bolts. Always install new EBCM bolts with the new BPMV. Tighten the 4 bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2 way ABS pump motor connector to the EBCM. 4. Install the BPMV (1) to EHCU bracket (3). 5. Install the BPMV (1) to bracket retaining bolts (4). Tighten the bolts to 9 Nm (7 ft. lbs.). 6. Install the EHCU to the vehicle frame (5). Tighten the three EHCU bracket bolts (4) to 25 Nm (18 ft. lbs.). 7. Connect the 2 electrical harness connectors to the EBCM (1). Important: The brake pipes are held in place by a plastic bracket mounted to the frame. Make sure that the brake pipes stay in the correct place for proper reassembly. 8. Install the 5 brake pipes to the BPMV (6). Tighten the brake pipe fittings to 25 Nm (18 ft. lbs.). 9. Bleed the brake system. 10. Bleed the brake system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Diagrams Inverting Driver Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 8631 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Service and Repair > Stabilitrak Traction Control Switch: Service and Repair Stabilitrak Traction Control Switch Replacement (Stabilitrak) Removal Procedure 1. Remove Instrument Panel (IP) bezel. 2. Gently lift the retaining tabs (2) and remove the stabilitrak switch (3) from the instrument panel (IP) assembly (1). 3. Disconnect the harness connector from the stabilitrak switch. Installation Procedure 1. Connect the harness connector to the stabilitrak switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Service and Repair > Stabilitrak > Page 8634 2. Install the stabilitrak switch (3) into the Instrument Panel (IP) assembly (1) 3. Ensure that the switch is secure into both retaining tabs (2). 4. Install instrument panel (IP) bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Service and Repair > Stabilitrak > Page 8635 Traction Control Switch: Service and Repair Traction Control Traction Control Switch Replacement (Traction Control) Removal Procedure 1. Remove instrument panel (IP) bezel. 2. Gently lift the switch retaining tabs (1) and remove the traction control switch (2) from the Instrument Panel (IP) assembly (3). 3. Disconnect the harness connector from the traction control switch. Installation Procedure 1. Connect the harness connector to the traction control switch. 2. Install the traction control switch (2) into the instrument panel (IP) assembly (3), making sure that all of the switch retaining tabs (1) are engaged. 3. Install Instrument Panel (IP) bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 05068C Date: 080306 Recall - Possible Front Wheel Speed Sensor Corrosion SAFETY Bulletin No.: 05068C Date: March 06, 2008 Subject: 05068C - FRONT WHEEL SPEED SENSOR CORROSION Models: 1999-2002 CHEVROLET SILVERADO 2000-2002 CHEVROLET TAHOE, SUBURBAN 2002 CHEVROLET AVALANCHE 1999-2002 GMC SIERRA 2000-2002 GMC YUKON, YUKON XL LOCATED IN THE SEVERE CORROSION AREAS LISTED BELOW Supercede: Some breakpoints in this bulletin have been revised. Additional vehicles that have moved into the severe corrosion areas have been added. Please discard all copies of bulletin 05068B, issued April 2006. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in the areas shown above. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is traveling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph) the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited a crash could occur. Correction Dealers are to inspect clean and treat the affected area. In some cases the front wheel speed sensor may require replacement. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8644 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8645 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra and 2000-2002 GMC Yukon, Yukon XL vehicles located in severe corrosion areas and built within the VIN breakpoints shown. Important: Dealers retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required order appropriate part from GMSPO. Customer Reimbursement All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center not by dealers. Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement. Claim Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8646 Submit a Product Recall Claim with the information shown. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. All unsold new vehicles in dealers possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers regardless of mileage age of vehicle or ownership from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory and for which there is no customer information indicated on the dealer listing are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose since the customer may not as yet have received the notification letter. In summary whenever a vehicle subject to this recall enters your vehicle inventory or is in your dealership for service in the future you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8647 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. 1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire or equivalent whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8648 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). ^ If the sensor mounting surface is NOT flat (1) the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2) the sensor IS to be reused. Proceed to Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8649 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed harness electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame upper control arm and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush sandpaper emery cloth scotch-brite or equivalent thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust or corrosion. 18. Using compressed air remove all debris from the bearing hub surface. 19. Using a clean shop towel clean the sensor and the 0-ring. Important: While the corrosion inhibitor is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes) apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8650 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 N.m (13 lb ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated after the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply threadlocker to the threads of the bolts. 28. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles - 175 N.m (129 lb ft) ^ 2500 Series vehicles - 300 N.m (221 lb ft) 29. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 N.m (140 lb ft). 30. Complete Steps 21-30 on the opposite side front wheel speed sensor. 31. Lower the vehicle. 32. With the engine OFF gradually apply the brake pedal to approximately 2/3 of its travel distance. 33. Slowly release the brake pedal. 34. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8651 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > NHTSA05V379000 > Aug > 05 > Recall 05V379000: Wheel Speed Sensor Cleaning Wheel Speed Sensor: Recalls Recall 05V379000: Wheel Speed Sensor Cleaning MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Avalanche 1999-2002 Chevrolet/Silverado 1999-2002 Chevrolet/Suburban 1999-2002 Chevrolet/Tahoe 1999-2002 GMC/Sierra 1999-2002 GMC/Yukon 1999-2002 GMC/Yukon XL 1999-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBE : 05V379000 MFG'S REPORT DATE: August 29, 2005 COMPONENT: Service Brakes, Hydraulic: Antilock POTENTIAL NUMBER OF UNITS AFFECTED: 804000 SUMMARY: Certain pickup trucks and sport utility vehicles may experience unwanted Antilock Brake System (ABS) activation. This condition is more likely to occur in environmentally corrosive areas. This recall will be launched in the "SALT BELT" states of Connecticut, Illinois, Indiana, Massachusetts, Maine, Michigan, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont and West Virginia only. CONSEQUENCE: This can cause increased stopping distances during low-speed brake applications, which could result in a crash. REMEDY: Dealers are to remove the wheel speed sensor and thoroughly clean the wheel speed sensor mounting surface on the bearing, apply rust inhibitor to the cleaned surface, grease the mounting surface, reinstall the wheel speed sensor, and check the peak-to-peak output voltage to ensure the wheel speed signal is within specifications. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05068. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 04094 Date: 050125 Recall - Front Wheel Speed Sensor Corrosion Product Safety - Front Wheel Speed Sensor Corrosion # 04094 - (Jan 25, 2005) Models: 1999-2002 Chevrolet Silverado 2000-2002 Chevrolet Tahoe, Suburban 2002 Chevrolet Avalanche 1999-2002 GMC Sierra 2000-2002 GMC Yukon, Yukon XL Located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, Prince Edward Island Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is travelling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph), the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited, a crash could occur. Correction Dealers are to clean and treat the affected area, and in some cases, replace the front wheel speed sensor. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8660 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8661 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required, order appropriate part from GMSPO. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8662 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by January 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. ^ Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8663 Claim Information Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8664 not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. A. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. B. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. C. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8665 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped, remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinist's scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8666 ^ If the sensor mounting surface is NOT flat (1), the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2), the sensor IS to be reused. Proceed to Step 16. 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed sensor electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame, upper control arm, and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush, sandpaper, emery cloth, scotch brite, or equivalent, thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust of corrosion. 18. Using compressed air, remove all debris from the bearing hub surface. 19. Using a clean shop towel, clean the sensor and the 0-ring. Important: While the corrosion is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin, to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 Nm (13 lb-ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmVs. If the reading is less than Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8667 350 ACmVs, the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated afier the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 28. Remove all traces of the original adhesive patch. A. Clean the threads of the bolt with brake parts cleaner, or the equivalent, and allow to dry. B. Apply threadlocker to the threads of the bolts. 29. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles -- 175 Nm (129 lb-ft) ^ 2500 Series vehicles -- 300 Nm (221 lb-ft) 30. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 Nm (140 lb-ft). 31. Complete Steps 21-30 on the opposite side front wheel speed sensor. 32. Lower the vehicle. 33. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 34. Slowly release the brake pedal. 35. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8668 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: Customer Interest Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 8674 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 8680 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 05068C Date: 080306 Recall - Possible Front Wheel Speed Sensor Corrosion SAFETY Bulletin No.: 05068C Date: March 06, 2008 Subject: 05068C - FRONT WHEEL SPEED SENSOR CORROSION Models: 1999-2002 CHEVROLET SILVERADO 2000-2002 CHEVROLET TAHOE, SUBURBAN 2002 CHEVROLET AVALANCHE 1999-2002 GMC SIERRA 2000-2002 GMC YUKON, YUKON XL LOCATED IN THE SEVERE CORROSION AREAS LISTED BELOW Supercede: Some breakpoints in this bulletin have been revised. Additional vehicles that have moved into the severe corrosion areas have been added. Please discard all copies of bulletin 05068B, issued April 2006. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in the areas shown above. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is traveling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph) the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited a crash could occur. Correction Dealers are to inspect clean and treat the affected area. In some cases the front wheel speed sensor may require replacement. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8685 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8686 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra and 2000-2002 GMC Yukon, Yukon XL vehicles located in severe corrosion areas and built within the VIN breakpoints shown. Important: Dealers retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required order appropriate part from GMSPO. Customer Reimbursement All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center not by dealers. Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement. Claim Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8687 Submit a Product Recall Claim with the information shown. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. All unsold new vehicles in dealers possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers regardless of mileage age of vehicle or ownership from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory and for which there is no customer information indicated on the dealer listing are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose since the customer may not as yet have received the notification letter. In summary whenever a vehicle subject to this recall enters your vehicle inventory or is in your dealership for service in the future you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8688 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. 1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire or equivalent whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8689 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). ^ If the sensor mounting surface is NOT flat (1) the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2) the sensor IS to be reused. Proceed to Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8690 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed harness electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame upper control arm and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush sandpaper emery cloth scotch-brite or equivalent thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust or corrosion. 18. Using compressed air remove all debris from the bearing hub surface. 19. Using a clean shop towel clean the sensor and the 0-ring. Important: While the corrosion inhibitor is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes) apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8691 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 N.m (13 lb ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated after the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply threadlocker to the threads of the bolts. 28. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles - 175 N.m (129 lb ft) ^ 2500 Series vehicles - 300 N.m (221 lb ft) 29. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 N.m (140 lb ft). 30. Complete Steps 21-30 on the opposite side front wheel speed sensor. 31. Lower the vehicle. 32. With the engine OFF gradually apply the brake pedal to approximately 2/3 of its travel distance. 33. Slowly release the brake pedal. 34. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8692 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > NHTSA05V379000 > Aug > 05 > Recall 05V379000: Wheel Speed Sensor Cleaning Wheel Speed Sensor: All Technical Service Bulletins Recall 05V379000: Wheel Speed Sensor Cleaning MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Avalanche 1999-2002 Chevrolet/Silverado 1999-2002 Chevrolet/Suburban 1999-2002 Chevrolet/Tahoe 1999-2002 GMC/Sierra 1999-2002 GMC/Yukon 1999-2002 GMC/Yukon XL 1999-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBE : 05V379000 MFG'S REPORT DATE: August 29, 2005 COMPONENT: Service Brakes, Hydraulic: Antilock POTENTIAL NUMBER OF UNITS AFFECTED: 804000 SUMMARY: Certain pickup trucks and sport utility vehicles may experience unwanted Antilock Brake System (ABS) activation. This condition is more likely to occur in environmentally corrosive areas. This recall will be launched in the "SALT BELT" states of Connecticut, Illinois, Indiana, Massachusetts, Maine, Michigan, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont and West Virginia only. CONSEQUENCE: This can cause increased stopping distances during low-speed brake applications, which could result in a crash. REMEDY: Dealers are to remove the wheel speed sensor and thoroughly clean the wheel speed sensor mounting surface on the bearing, apply rust inhibitor to the cleaned surface, grease the mounting surface, reinstall the wheel speed sensor, and check the peak-to-peak output voltage to ensure the wheel speed signal is within specifications. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05068. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 04094 Date: 050125 Recall - Front Wheel Speed Sensor Corrosion Product Safety - Front Wheel Speed Sensor Corrosion # 04094 - (Jan 25, 2005) Models: 1999-2002 Chevrolet Silverado 2000-2002 Chevrolet Tahoe, Suburban 2002 Chevrolet Avalanche 1999-2002 GMC Sierra 2000-2002 GMC Yukon, Yukon XL Located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, Prince Edward Island Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is travelling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph), the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited, a crash could occur. Correction Dealers are to clean and treat the affected area, and in some cases, replace the front wheel speed sensor. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8701 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8702 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required, order appropriate part from GMSPO. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8703 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by January 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. ^ Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8704 Claim Information Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8705 not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. A. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. B. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. C. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8706 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped, remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinist's scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8707 ^ If the sensor mounting surface is NOT flat (1), the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2), the sensor IS to be reused. Proceed to Step 16. 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed sensor electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame, upper control arm, and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush, sandpaper, emery cloth, scotch brite, or equivalent, thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust of corrosion. 18. Using compressed air, remove all debris from the bearing hub surface. 19. Using a clean shop towel, clean the sensor and the 0-ring. Important: While the corrosion is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin, to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 Nm (13 lb-ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmVs. If the reading is less than Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8708 350 ACmVs, the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated afier the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 28. Remove all traces of the original adhesive patch. A. Clean the threads of the bolt with brake parts cleaner, or the equivalent, and allow to dry. B. Apply threadlocker to the threads of the bolts. 29. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles -- 175 Nm (129 lb-ft) ^ 2500 Series vehicles -- 300 Nm (221 lb-ft) 30. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 Nm (140 lb-ft). 31. Complete Steps 21-30 on the opposite side front wheel speed sensor. 32. Lower the vehicle. 33. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 34. Slowly release the brake pedal. 35. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8709 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 8715 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 05068C Date: 080306 Recall - Possible Front Wheel Speed Sensor Corrosion SAFETY Bulletin No.: 05068C Date: March 06, 2008 Subject: 05068C - FRONT WHEEL SPEED SENSOR CORROSION Models: 1999-2002 CHEVROLET SILVERADO 2000-2002 CHEVROLET TAHOE, SUBURBAN 2002 CHEVROLET AVALANCHE 1999-2002 GMC SIERRA 2000-2002 GMC YUKON, YUKON XL LOCATED IN THE SEVERE CORROSION AREAS LISTED BELOW Supercede: Some breakpoints in this bulletin have been revised. Additional vehicles that have moved into the severe corrosion areas have been added. Please discard all copies of bulletin 05068B, issued April 2006. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in the areas shown above. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is traveling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph) the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited a crash could occur. Correction Dealers are to inspect clean and treat the affected area. In some cases the front wheel speed sensor may require replacement. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8721 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8722 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra and 2000-2002 GMC Yukon, Yukon XL vehicles located in severe corrosion areas and built within the VIN breakpoints shown. Important: Dealers retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required order appropriate part from GMSPO. Customer Reimbursement All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center not by dealers. Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement. Claim Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8723 Submit a Product Recall Claim with the information shown. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. All unsold new vehicles in dealers possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers regardless of mileage age of vehicle or ownership from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory and for which there is no customer information indicated on the dealer listing are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose since the customer may not as yet have received the notification letter. In summary whenever a vehicle subject to this recall enters your vehicle inventory or is in your dealership for service in the future you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8724 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. 1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire or equivalent whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8725 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). ^ If the sensor mounting surface is NOT flat (1) the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2) the sensor IS to be reused. Proceed to Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8726 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed harness electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame upper control arm and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush sandpaper emery cloth scotch-brite or equivalent thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust or corrosion. 18. Using compressed air remove all debris from the bearing hub surface. 19. Using a clean shop towel clean the sensor and the 0-ring. Important: While the corrosion inhibitor is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes) apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8727 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 N.m (13 lb ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated after the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply threadlocker to the threads of the bolts. 28. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles - 175 N.m (129 lb ft) ^ 2500 Series vehicles - 300 N.m (221 lb ft) 29. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 N.m (140 lb ft). 30. Complete Steps 21-30 on the opposite side front wheel speed sensor. 31. Lower the vehicle. 32. With the engine OFF gradually apply the brake pedal to approximately 2/3 of its travel distance. 33. Slowly release the brake pedal. 34. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 8728 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > NHTSA05V379000 > Aug > 05 > Recall 05V379000: Wheel Speed Sensor Cleaning Wheel Speed Sensor: All Technical Service Bulletins Recall 05V379000: Wheel Speed Sensor Cleaning MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Avalanche 1999-2002 Chevrolet/Silverado 1999-2002 Chevrolet/Suburban 1999-2002 Chevrolet/Tahoe 1999-2002 GMC/Sierra 1999-2002 GMC/Yukon 1999-2002 GMC/Yukon XL 1999-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBE : 05V379000 MFG'S REPORT DATE: August 29, 2005 COMPONENT: Service Brakes, Hydraulic: Antilock POTENTIAL NUMBER OF UNITS AFFECTED: 804000 SUMMARY: Certain pickup trucks and sport utility vehicles may experience unwanted Antilock Brake System (ABS) activation. This condition is more likely to occur in environmentally corrosive areas. This recall will be launched in the "SALT BELT" states of Connecticut, Illinois, Indiana, Massachusetts, Maine, Michigan, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont and West Virginia only. CONSEQUENCE: This can cause increased stopping distances during low-speed brake applications, which could result in a crash. REMEDY: Dealers are to remove the wheel speed sensor and thoroughly clean the wheel speed sensor mounting surface on the bearing, apply rust inhibitor to the cleaned surface, grease the mounting surface, reinstall the wheel speed sensor, and check the peak-to-peak output voltage to ensure the wheel speed signal is within specifications. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05068. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 04094 Date: 050125 Recall - Front Wheel Speed Sensor Corrosion Product Safety - Front Wheel Speed Sensor Corrosion # 04094 - (Jan 25, 2005) Models: 1999-2002 Chevrolet Silverado 2000-2002 Chevrolet Tahoe, Suburban 2002 Chevrolet Avalanche 1999-2002 GMC Sierra 2000-2002 GMC Yukon, Yukon XL Located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, Prince Edward Island Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is travelling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph), the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited, a crash could occur. Correction Dealers are to clean and treat the affected area, and in some cases, replace the front wheel speed sensor. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8737 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8738 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required, order appropriate part from GMSPO. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8739 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by January 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. ^ Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8740 Claim Information Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8741 not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. A. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. B. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. C. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8742 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped, remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinist's scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8743 ^ If the sensor mounting surface is NOT flat (1), the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2), the sensor IS to be reused. Proceed to Step 16. 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed sensor electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame, upper control arm, and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush, sandpaper, emery cloth, scotch brite, or equivalent, thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust of corrosion. 18. Using compressed air, remove all debris from the bearing hub surface. 19. Using a clean shop towel, clean the sensor and the 0-ring. Important: While the corrosion is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin, to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 Nm (13 lb-ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmVs. If the reading is less than Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8744 350 ACmVs, the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated afier the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 28. Remove all traces of the original adhesive patch. A. Clean the threads of the bolt with brake parts cleaner, or the equivalent, and allow to dry. B. Apply threadlocker to the threads of the bolts. 29. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles -- 175 Nm (129 lb-ft) ^ 2500 Series vehicles -- 300 Nm (221 lb-ft) 30. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 Nm (140 lb-ft). 31. Complete Steps 21-30 on the opposite side front wheel speed sensor. 32. Lower the vehicle. 33. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 34. Slowly release the brake pedal. 35. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 8745 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 8746 Wheel Speed Sensor: Specifications Front Wheel Speed Sensor Mounting Bolt ............................................................................................................................................... 18 Nm (13 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 8747 Wheel Speed Sensor - RF (4WD) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > LF Wheel Speed Sensor (WSS) - LF Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > LF > Page 8750 Wheel Speed Sensor (WSS) - RF Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 8751 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor (2). 4. Remove the Wheel Speed Sensor (WSS) mounting bolt. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 5. Remove the wheel speed sensor (5) from the hub/bearing assembly (4). 6. Remove the WSS cable mounting clip from the knuckle. 7. Remove the WSS cable mounting clip from the upper control arm. 8. Remove the WSS cable mounting clip from the frame attachment point. 9. Remove the WSS cable electrical connector. Installation Procedure 1. Install the WSS (5) into the hub/bearing assembly (4). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the WSS mounting bolt. Tighten the WSS mounting bolt to 18 Nm (13 ft. lbs.). 3. Install the WSS cable mounting clip to the knuckle. 4. Install the WSS cable mounting clip to the upper control arm. 5. Install the WSS cable mounting clip to the frame attachment point. 6. Connect the WSS cable electrical connector. 7. Install the brake rotor (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 8752 8. Install the tire and wheel. 9. Return to Diagnostic Starting Point - Antilock Brake System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Specifications Yaw Rate Sensor: Specifications Yaw Rate Sensor/Lateral Accelerometer Nut ........................................................................................................................................ 10 Nm (89 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Specifications > Page 8756 Yaw Rate Sensor: Service and Repair Yaw Rate Sensor/Lateral Accelerometer Replacement Removal Procedure 1. Remove the front floor console bezel. 2. Disconnect the yaw rate sensor/lateral accelerometer electrical connector. 3. Remove the 3 yaw rate sensor/lateral accelerometer nuts. 4. Remove the yaw rate sensor/lateral accelerometer from the vehicle. Installation Procedure Important: Use care not to bend or distort the bracket that supports the yaw rate sensor/lateral accelerometer. 1. Install the yaw rate sensor/lateral accelerometer to the bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 yaw rate sensor/lateral accelerometer nuts to the bracket. Tighten the nuts to 10 Nm (89 inch lbs.). 3. Connect the yaw rate sensor/lateral accelerometer electrical connector. 4. Install the front floor bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure W/JL4 ABS Automated Bleed Procedure (W/JL4) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: This procedure is ONLY to be performed on vehicles equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding before proceeding. 1. Install a scan tool. 2. Apply the park brake fully. 3. Start the engine and allow the engine to idle. 4. Depress the brake pedal firmly and maintain steady pressure on the pedal. 5. From the VSES Special Functions menu on the scan tool, select the Automated Bleed procedure. 6. Send the automated bleed command by pressing the On key on the scan tool. After initiating the automated bleed procedure, the brake pedal will drop and then pulse back up, 8 times, while the LPA is being purged of any trapped air. 7. Fill the brake master cylinder reservoir with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half full during this bleeding procedure and add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, when cap removal is necessary. 8. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 9. Install a transparent hose over the end of the bleeder valve. 10. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container. 11. Have an assistant slowly depress the brake pedal and maintain pressure on the pedal. 12. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 13. Tighten the bleeder valve when full brake pedal travel has occurred. 14. Have the assistant slowly release the brake pedal. Wait 5 seconds before proceeding to the next step. 15. Repeat steps 11-14 until all air is purged from the same wheel hydraulic circuit. 16. After all air has been purged from the right rear hydraulic circuit and the bleeder valve is tightened securely, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 17. Repeat steps 9-15 at the left rear wheel hydraulic circuit. 18. After all air has been purged from the right rear hydraulic circuit and the bleeder valve is tightened securely, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 19. Repeat steps 9-15 at the right front wheel hydraulic circuit. 20. After all air has been purged from the right rear hydraulic circuit and the bleeder valve is tightened securely, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 21. Repeat steps 9-15 at the left front wheel hydraulic circuit. 22. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container. 23. Install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 24. Install a transparent hose over the end of the bleeder valve. 25. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container. 26. Use the procedure below to purge the Medium Pressure Accumulator (MPA) of any trapped air. 26.1. With the engine still idling, select the Bleed MPA procedure from the VSES Special Functions menu. 26.2. Send the bleed MPA command by pressing the On key on the scan tool. 26.3. Open the LEFT FRONT wheel hydraulic circuit bleeder valve. Important: Ensure that you fully release the brake pedal for at least 2 seconds between pedal strokes. The amount of accumulated time between pedal strokes is calculated to deliver the most thorough bleed of the Medium Pressure Accumulator (MPA). 26.4. Depress the brake pedal as far as possible using a smooth stroke. 26.5. Release the brake pedal using a smooth stroke. 26.6. Repeat steps 26.4-26.5 until 13 complete pedal strokes have been performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8761 Important: Observe the MPA switch parameter as the pedal strokes are being performed. The MPA switch parameter should change from Uncharged to Charged several times during the first 8 or 9 strokes. After approximately 10 pedal strokes, the MPA switch parameter should remain Charged. If the parameter does not change, repeat all of step 26. 26.7. The valves within the BPMV are active for the first 13 complete pedal strokes to enable the MPA to be filled and discharged, forcing any trapped air out of the LEFT FRONT wheel hydraulic circuit bleeder valve. 26.8. Continue to depress and release the brake pedal while observing the fluid within the transparent hose. When no air is observed exiting the hydraulic system, proceed to the next step. 26.9. Depress the brake pedal and maintain pedal position. 26.10. Have an assistant tighten the bleeder valve. 26.11. Release the brake pedal. 27. Remove the scan tool from the vehicle. 28. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container. 29. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 30. If the brake pedal feels spongy, repeat this entire bleed procedure. If the brake pedal still feels spongy after repeating this procedure, inspect the brake system for external leaks. 31. Observe the brake warning indicator to determine whether or not the indicator remains illuminated. 32. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. W/O JL4 ABS Automated Bleed Procedure (w/o JL4) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: This procedure may be performed on all vehicles EXCEPT those equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. 15. Drive the vehicle to exceed 13 kPa (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8762 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Manual Hydraulic Brake System Bleeding (Manual) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder- loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely- after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely- after all air has been purged from the left rear hydraulic circuit- install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely- after all air has been purged from the right front hydraulic circuitinstall a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8763 Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Pressure Hydraulic Brake System Bleeding (Pressure) Tools Required ^ J29532 Diaphragm Type Brake Pressure Bleeder, or equivalent ^ J35589-A Brake Pressure Bleeder Adapter Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder- after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J29532, or equivalent. Add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J29532, or equivalent, to the J35589-A. 8. Charge the J29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit- install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuitinstall a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8764 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J35589-A. 23. Remove the J35589-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8765 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Brake Pedal Bolt .................................................................................................................................. ..................................................... 47 Nm (35 ft. lbs.) Brake Pedal Maximum Travel ................. Specification with 445 N (100 lbs) of force applied to the brake pedal, the ignition OFF, and the brake booster power reserve depleted. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 8769 Brake Pedal Assy: Service and Repair Brake Pedal Replacement Removal Procedure 1. Remove the pushrod retaining clip (4). 2. Remove the stoplamp switch (2) and the pushrod (3) from the brake pedal stud (1). 3. Remove the nut from the brake pedal bolt. 4. Remove the brake pedal bolt. 5. Remove the brake pedal. Installation Procedure 1. Install the brake pedal. 2. Install the brake pedal bolt. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 8770 3. Install the nut to the brake pedal bolt. Hold the nut with a wrench and tighten the brake pedal bolt to 47 Nm (35 ft. lbs.). 4. Install the pushrod (3) and the stoplamp switch (2) to the brake pedal pin (1). 5. Install the pushrod retaining clip (4). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Testing and Inspection Brake Warning Indicator: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Hydraulic System Testing and Inspection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement Brake Caliper: Service and Repair Brake Caliper Bracket Replacement Front Brake Caliper Bracket Replacement - Front Removal Procedure Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the brake pads. 3. Remove the anti-rattle clips from the brake caliper bracket. 4. Remove the brake caliper bracket mounting bolts (2). 5. Remove the brake caliper bracket (1). 6. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 7. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8779 1. Install the brake caliper bracket (1). 2. Perform the following procedure before installing the brake caliper bracket mounting bolts. ^ Remove all traces of the original adhesive patch. ^ Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. ^ Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the caliper bracket mounting bolts (2). ^ Tighten the brake caliper bracket to knuckle bolt to 175 Nm (121 ft. lbs.) for the 15 Series. ^ Tighten the brake caliper bracket to knuckle bolts to 300 Nm (221 ft. lbs.) for 25 Series. 4. Install the anti-rattle clips to the brake caliper bracket. 5. Install the brake pads to the brake caliper bracket. ^ Install the inner pad-1 wear indicator. ^ Install the inner pad-2 wear indicators. 6. Slide the brake pads in until they contact the rotor. 7. Install the brake caliper. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 1-11 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Rear Brake Caliper Bracket Replacement - Rear Removal Procedure Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8780 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the brake pads. 3. Remove the anti-rattle clips from the brake caliper bracket. 4. Remove the brake caliper bracket mounting bolts (2). 5. Remove the brake caliper bracket (1). 6. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 7. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure 1. Install the brake caliper bracket (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8781 2. Perform the following procedure before installing the brake caliper bracket mounting bolts. ^ Remove all traces of the original adhesive patch. ^ Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. ^ Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the caliper bracket mounting bolts (2). ^ For vehicles equipped with JC5/JH5 brake systems, tighten the caliper bracket mounting bolts to 200 Nm (148 ft. lbs.). ^ For vehicles equipped with JH6 brake systems, tighten the caliper bracket mounting bolts to 165 Nm (122 ft. lbs.). 4. Install the anti-rattle clips to the brake caliper bracket. 5. Install the brake pads to the brake caliper bracket. 6. Slide the brake pads in until they contact the rotor. 7. Install the brake caliper. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 7-8 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8782 Brake Caliper: Service and Repair Brake Caliper Overhaul Front Brake Caliper Overhaul - Front Disassembly Procedure Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. 1. Remove the brake caliper from the vehicle. 2. Place a thin piece of wood in front of the piston in order to prevent damage. Remove the piston by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the piston boot. 4. Remove the piston seal. 5. Remove the brake caliper bleed screw cap. 6. Remove the brake caliper bleed screw. 7. Inspect the brake caliper bore and the piston seal groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal area, replace the brake caliper housing. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8783 8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if necessary. 9. Clean all of the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket. 10. Clean all of the parts not included in the repair kit with denatured alcohol. 11. Dry all of the parts with filtered Unlubricated compressed air. 12. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve. Assembly Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the brake caliper bleed screw. Tighten the brake caliper bleed screw to 12 Nm (106 inch lbs.). 2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seals and the brake caliper bore seal grooves with brake fluid, GM P/N 12388967 (Canadian P/N 992667). 4. Install new seals into the brake caliper bore seal grooves. 5. Ensure that the seals are not twisted. 6. Lubricate the brake caliper bores and the pistons with brake fluid, GM P/N 12388967 (Canadian P/N 992667). 7. Install the boot and piston. 7.1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. 7.2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. 7.3. Push down the piston to the bottom of the brake caliper bore. 7.4. Ensure the boot seats properly into the piston groove and into the groove in the brake caliper bore. 7.5. Repeat steps 5 and 6 for the remaining piston. 8. Install the brake caliper to the vehicle. Rear Brake Caliper Overhaul - Rear Disassembly Procedure Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. 1. Remove the brake caliper from the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8784 2. Place a thin piece of wood in front of the piston in order to prevent damage. Remove the piston by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the piston boot. 4. Remove the piston seal. 5. Remove the brake caliper bleed screw cap. 6. Remove the brake caliper bleed screw. 7. Inspect the brake caliper bore and the piston seal groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal area, replace the brake caliper housing. 8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed. 9. Clean all the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket. 10. Clean all the parts not included in the repair kit with denatured alcohol. 11. Dry all the parts with filtered Unlubricated compressed air. 12. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve. Assembly Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8785 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the brake caliper bleed screw. Tighten the brake caliper bleed screw to 12 Nm (106 inch lbs.). 2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid, GM P/N 12388967 (Canadian P/N 992667). 4. Install new the seal into the brake caliper bore seal groove. 5. Ensure that the seal is not twisted. 6. Lubricate the brake caliper bore and the piston with brake fluid, GM P/N 12388967 (Canadian P/N 992667). 7. Install the boot and the piston. 7.1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. 7.2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. 7.3. Push down the piston to the bottom of the brake caliper bore. 7.4. Ensure that the boot properly seats into the piston groove and into the groove in the brake caliper bore. 7.5. Repeat steps 5 and 6 for the remaining piston. 8. Install the brake caliper to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8786 Brake Caliper: Service and Repair Brake Caliper Replacement Front Brake Caliper Replacement - Front Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. ^ Remove the C-clamp from the caliper. 7. Clean all dirt and foreign material from the brake hose end. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. 8. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 10. Remove the brake hose from the caliper. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8787 11. Remove the 2 brake caliper mounting bolts. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result 12. Remove the brake caliper from the brake caliper mounting bracket. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the brake caliper to the brake caliper mounting bracket. 2. Install the 2 brake caliper mounting bolts. Tighten the bolts to 108 Nm (80 ft. lbs.). 3. Remove the rubber cap or plug from the exposed brake hose fitting end. Important: Install 2 New copper brake hose gaskets. 4. Assemble the 2 New copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8788 5. Install the brake hose to caliper bolt to the brake caliper. Tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Rear Brake Caliper Replacement - Rear Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level then no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level then remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. ^ Remove the C-clamp from the caliper. 7. Clean all dirt and foreign material from the brake hose end. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8789 8. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 10. Remove the caliper guide pin bolts. 11. Remove the brake caliper from the vehicle. 12. Inspect the caliper assembly. Installation Procedure Important: Use denatured alcohol to clean the outside surface of caliper boots before installing new brake pads. 1. If you are installing new brake pads use a C-clamp in order to compress the pistons to the bottom of the caliper bores. Use the old brake pad, a metal plate or a wooden block across the face of the pistons in order to protect the pistons and the caliper boots. Important: Use a small flat-bladed tool and lift the inner edge of the caliper boots next to both pistons to release any trapped air. 2. Ensure that the caliper boots are below the level of the face of both pistons. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8790 3. Install the brake caliper to the brake caliper mounting bracket. 4. Perform the following procedure before installing the caliper guide pin bolts. 4.1. Remove all traces of the original adhesive patch. 4.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 4.3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 5. Install the brake caliper mounting bolts. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the brake caliper guide pin bolts - rear 15 Series. Tighten the to 42 Nm (31 ft. lbs.). 7. Remove the rubber cap or plug from the exposed brake hose fitting end. Important: Install 2 New copper brake hose gaskets. 8. Assemble the 2 New copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 9. Connect the brake hose at the caliper by installing the brake hose to caliper bolt. Tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.). 10. Bleed the hydraulic brake system. 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. Fill the master cylinder reservoir to the proper level with clean brake fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8791 Brake Caliper: Service and Repair Disc Brake Hardware Replacement Front Disc Brake Hardware Replacement - Front Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 4. Remove the disc brake pads from the disc brake caliper mounting bracket. 5. Remove the disc brake pad retainers from the disc brake caliper mounting bracket. 6. Inspect the disc brake hardware. 7. Remove the caliper pin boots (4) from the disc brake caliper mounting bracket (3). Installation Procedure 1. Lubricate the front brake caliper bushings, bolts and seals with high temperature silicone brake lubricant. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8792 2. Install the caliper pin boots (4) to the disc brake caliper mounting bracket (3). 3. Install the disc brake pad retainers to the disc brake caliper mounting bracket. 4. Install the disc brake pads to the disc brake caliper mounting bracket. 5. Install the disc brake caliper to the caliper mounting bracket. 6. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 7. Slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 7-8 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Rear Disc Brake Replacement - Rear Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8793 Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 3. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 4. Remove the disc brake pads from the disc brake caliper bracket. 5. Remove the disc brake pad retainers from the disc brake caliper bracket. 6. Remove the caliper pins (5) from the disc brake caliper mounting bracket (3). 7. Remove the caliper pin boots (4) from the disc brake caliper mounting bracket. 8. Inspect the disc brake hardware. Installation Procedure 1. Lubricate the brake caliper, bushings, bolts and seals with high temperature silicone brake lubricant. 2. Install the caliper pin boots (4) to the disc brake caliper mounting bracket. 3. Install the caliper pins (5) to the disc brake caliper mounting bracket (3). 4. Install the disc brake pad retainers to the disc brake caliper bracket. 5. Install the disc brake pads to the disc brake caliper bracket. 6. Install the disc brake caliper to the mounting bracket. 7. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 7-8 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Replace the disc brake pads when the friction surface (3) is worn to within 0.76 mm (0.030 inch) of the mounting plates. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front Brake Pads Replacement - Front Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Inspect the caliper operation. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 7. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 8. Remove the brake pads from the caliper mounting bracket. 9. Remove and discard the anti-rattle clips from the brake caliper mounting bracket. 10. Inspect the caliper and mounting bracket. Installation Procedure 1. Install new anti-rattle clips to the inside ends of the caliper mounting bracket. 2. Install the brake pads to the caliper mounting bracket. ^ Install the inner pad-1 wear indicator. ^ Install the outer pad-2 wear indicators. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 8799 3. Install the brake caliper. 4. Install the tire and wheel assembly. 5. Remove the safety stands. 6. Lower the vehicle. 7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 7-8 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 10. Fill the master cylinder reservoir to the proper level with clean brake fluid. 11. Burnish the brake pads and rotors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 8800 Brake Pad: Service and Repair Rear Brake Pads Replacement - Rear Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Inspect the caliper operation. 7. Place a c-clamp as shown. Slowly bottom the pistons of the caliper. It may be necessary to reposition the c-clamp to allow both of the pistons to bottom into the caliper bores. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 8. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 9. Inspect the caliper assembly. 10. Remove the brake pads from the brake caliper bracket. 11. Remove and discard the anti-rattle clips from the brake caliper mounting bracket. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 8801 1. Install the anti-rattle clips to the brake caliper bracket. 2. Install the brake pads to the brake caliper bracket. ^ Install the inner pad-1 wear indicator. ^ Install the outer pad-2 wear indicators. 3. Install the brake caliper to the mounting bracket. 4. Install the tire and wheel assembly. 5. Lower the vehicle. 6. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 7. Slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 7-8 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. 10. Burnish the brakes pads and rotors as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 8802 Brake Pad: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to Famous personal Injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8807 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8808 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8809 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8810 WARRANTY INFORMATION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8811 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8812 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8813 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8814 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8815 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8816 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8817 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8818 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8819 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8820 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 8821 Brake Rotor/Disc: Specifications Front Brakes JC5/JH5 All Rotor Discard Thickness * ............................................................................................................................................................. 27.50 mm (1.082 inch) Rotor Minimum Allowable Thickness After Refinish ....................................................................................................................... 28 0 mm (1.10 inch) Rotor Thickness-new ........................................................................................................................... .............................................. 29.0 mm (1.14 inch) Rotor Maximum Allowable Lateral Runout .................................................................................................................................... 0.13 mm (0.005 inch) Rotor Maximum Allowable Scoring ................................................................................................................................................ 1.50 mm (0.139 inch) Rotor Maximum Allowable Thickness Variation .......................................................................................................................... 0.025 mm (0.001 inch) Front Brakes JH6 Rotor Discard Thickness * ............................................................................................................................................................. 36.50 mm (1.437 inch) Rotor Minimum Allowable Thickness After Refinish ....................................................................................................................... 37.0 mm (1.46 inch) Rotor Thickness-new ........................................................................................................................... .............................................. 38.0 mm (1.50 inch) Rotor Maximum Allowable Lateral Runout .................................................................................................................................... 0.13 mm (0.005 inch) Rotor Maximum Allowable Scoring ................................................................................................................................................ 1.50 mm (0.139 inch) Rotor Maximum Allowable Thickness Variation .......................................................................................................................... 0.025 mm (0.001 inch) Rear Brakes JC5/JH5 Utility Only Rotor Discard Thickness* .............................................................................................................................................................. 28.50 mm (1.122 inch) Rotor Minimum Allowable Thickness After Refinish ..................................................................................................................... 29.0 mm (1.142 inch) Rotor Thickness-new ........................................................................................................................... ............................................ 30.0 mm (1.181 inch) Rotor Maximum Allowable Lateral Runout .................................................................................................................................... 0.13 mm (0.005 inch) Rotor Maximum Allowable Scoring ................................................................................................................................................ 1.50 mm (0.139 inch) Rotor Maximum Allowable Thickness Variation .......................................................................................................................... 0.025 mm (0.001 inch) Rear Brakes JH6 Rotor Discard Thickness * ............................................................................................................................................................. 27.50 mm (1.082 inch) Rotor Minimum Allowable Thickness After Refinish ..................................................................................................................... 28.0 mm (1.102 inch) Rotor Thickness-new ........................................................................................................................... ............................................ 29.0 mm (1.141 inch) Rotor Maximum Allowable Lateral Runout .................................................................................................................................... 0.13 mm (0.005 inch) Rotor Maximum Allowable Scoring ................................................................................................................................................ 1.50 mm (0.139 inch) Rotor Maximum Allowable Thickness Variation .......................................................................................................................... 0.025 mm (0.001 inch) * All brake rotors have a discard dimension cast into them Replace any rotor that does not meet this specification After refinishing the rotor, replace any rotor that does not meet the minimum or discard thickness specifications. Backing Plate Bolts .............................................................................................................................. ................................................ 135 Nm (100 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement Brake Rotor/Disc: Service and Repair Brake Rotor Replacement Front Brake Rotor Replacement - Front Tools Required ^ J41013 Rotor Resurfacing Kit ^ J42450-A Wheel Hub Resurfacing Kit Removal Procedure Notice: Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Use Goodwrench Brake Parts Cleaner, GM P/N 123777981 (Canadian P/N 10953463), or the equivalent, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents which may leave an oily residue. This residue is damaging to the brake lining and is flammable. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Mark the relationship of the rotor to the hub. 4. Remove the 2 brake caliper bracket mounting bolts. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and brake caliper mounting bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Remove the rotor retaining push nuts from the wheel studs, if applicable. 7. It may be necessary to strike the end of the hub or the rotor with a deadblow hammer to separate the rotor from the hub. 8. Remove the rotor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 8824 9. If the rotor is difficult to remove due to corrosion in the hub area use the following procedure to remove the rotor; 25 series only. ^ Clean all the surface areas and the threaded holes of contamination. ^ Generously apply penetrating oil or the equivalent to the hub/rotor area. ^ Insert (2) M10 x 1.5 bolts (jack screws) into the threaded holes of the rotor. ^ Tighten both bolts evenly to force the rotor from the hub. Installation Procedure Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange with the J42450 hub cleaning kit. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. 1. Use the J42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J41013 to clean all rust and contaminants from the inside diameter of the hub section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. Important: If the rotor was removed using the jack screw method you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 3. Align the rotor to its original position on the hub, if applicable, and install the rotor. 4. Install the caliper and caliper mounting bracket assembly. 5. Perform the following procedure before installing the brake caliper bracket mounting bolts. ^ Remove all traces of the original adhesive patch. ^ Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. ^ Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 8825 6. Install the 2 caliper bracket mounting bolts. ^ Tighten the brake caliper bracket mounting bolts to 175 Nm (121 ft. lbs.), 15 Series. ^ Tighten the brake caliper bracket mounting bolts to 300 Nm (221 ft. lbs.), 25 Series. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 10. Slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 9-10 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 12. Fill the master cylinder reservoir to the proper level with clean brake fluid. Rear Brake Rotor Replacement - Rear Removal Procedure Tools Required ^ J41013 Rotor Resurfacing Kit ^ J42450-A Wheel Hub Resurfacing Kit 1. Release the park brake. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. 4. Mark the relationship of the rotor to the hub. 5. Remove the brake caliper bracket mounting bolts. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 6. Remove the brake caliper and brake caliper bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 8826 hydraulic brake flexible hose from the caliper. 7. Remove the rotor retaining push nuts from the wheel studs, if applicable. 8. It may be necessary to strike the end of the hub or the rotor with a deadblow hammer to separate the rotor from the hub. 9. Remove the rotor by slowly fuming the rotor while pulling the rotor away from the axle. Installation Procedure Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange with the J42450 hub cleaning kit. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. 1. Use the J42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J41013 to clean all rust and contaminants from the inside diameter of the hub section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Install the rotor by slowly fuming the rotor while pushing the rotor towards the axle. 4. Install the caliper and the bracket as an assembly to the vehicle. 5. Perform the following procedure before installing the caliper bracket mounting bolts. ^ Remove all traces of the original adhesive patch. ^ Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. ^ Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the caliper bracket mounting bolts. ^ For the 15 Series, tighten the brake caliper bracket mounting bolts to 175 Nm (129 ft. lbs.). ^ For the 25 series, tighten the brake caliper bracket mounting bolts to 300 Nm (221 ft. lbs.). 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 10. Slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 9-10 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 12. Fill the master cylinder reservoir to the proper level with clean brake fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 8827 Brake Rotor/Disc: Service and Repair Disc Brake Splash Shield Replacement Front Disc Brake Splash Shield Replacement - Front Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the hub and bearing assembly. 4. Remove the splash shield, for 15 series. 5. Remove the splash shield, for 25 series. Installation Procedure 1. Install the splash shield, for 15 series. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 8828 2. Install the splash shield, for 25 series. 3. Install the hub and bearing assembly. 4. Install the tire and wheel assembly. 5. Remove the safety stands. 6. Lower the vehicle. Rear Disc Brake Backing Plate Replacement - Rear Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. 4. Relieve the tension from the park brake cables by loosening the nut at the equalizer. 5. Remove the rear park brake cable from the park brake actuator lever. 6. Remove the park brake cable from the mounting bracket by depressing the locking tabs. 7. Remove the rotor. 8. Remove the axle shaft. 9. Remove the park brake shoe. 10. Remove the backing plate nuts. 11. Remove the backing plate from axle housing flange. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 8829 1. Install the backing plate to the axle housing flange. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the backing plate nuts. Tighten the backing plate bolts to 135 Nm (100 ft. lbs.). 3. Install the park brake shoe. 4. Install the axle shaft. 5. Adjust the park brake shoe. 6. Install the rotor. 7. Install the park brake cable to the mounting bracket until the locking tabs snap into place. 8. Install the rear park brake cable to the park brake actuator lever. 9. Tighten the nut to the intermediate cable at the equalizer. Tighten the nut to 3.5 Nm (31 inch lbs.). 10. Install the tire and wheel assembly. 11. Remove the safety stands. 12. Lower vehicle. 13. Adjust park brake cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 8830 Brake Rotor/Disc: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to Famous personal Injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 8831 Brake Rotor/Disc: Service and Repair Brake Rotor Refinishing Brake Rotor Refinishing Tools Required ^ J41013 Rotor Resurfacing Kit ^ J42450-A Wheel Hub Resurfacing Kit 1. The disc brake rotors do not require refinishing as part of routine brake system service. Do not refinish disc brake rotors in an attempt to correct the following conditions: ^ Brake system noise - squeal, growl, groan ^ Uneven and/or premature disc brake pad wear ^ Superficial or cosmetic corrosion/rust of the disc brake rotor surface ^ Scoring of the disc brake rotor surface less than the maximum allowable specification 2. Disc brake rotors should only be refinished if the following conditions exist: ^ Excessive corrosion/rust and/or pitting ^ Cracks and/or heat spots ^ Excessive blueing discoloration ^ Scoring of the disc brake rotor surface in excess of the maximum allowable specification ^ Lateral runout in excess of the maximum allowable specification 3. Inspect each of the disc brake rotors and determine if the rotors can be refinished and remain above the minimum allowable thickness after refinish specification: 3.1. Inspect the thickness of each of the disc brake rotors. 3.2. Inspect each of the disc brake rotors for excessive surface wear and/or lateral runout. 4. If the rotors can be refinished, proceed with the rotor refinishing procedure. Important: Failure to clean the corrosion from the wheel bearing flange, brake rotor mating surface, and brake rotor mounting face may result in increased lateral runout of the brake rotor and brake system pulsation. 5. Use the J41013 in order to thoroughly clean any corrosion from the wheel bearing flange. 6. Use the J42450-A in order to thoroughly clean any corrosion/rust from the brake rotor mating surface and mounting face. 7. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris. 8. Ensure that any vibration dampening attachments are securely in place. 9. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces. 10. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or more of the way around the brake rotor surface on each side, the brake rotor is properly mounted to the lathe. 11. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount the rotor to the lathe. 12. Following the brake lathe manufacturer's instructions, refinish the brake rotor. 13. After each successive cut, inspect the brake rotor thickness. 14. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. 15. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 15.1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish 15.2. Using moderate pressure, apply the non-directional finish: ^ If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper ^ If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper 15.3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol or an equivalent brake cleaner 16. Remove the brake rotor from the brake lathe. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure W/JL4 ABS Automated Bleed Procedure (W/JL4) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: This procedure is ONLY to be performed on vehicles equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding before proceeding. 1. Install a scan tool. 2. Apply the park brake fully. 3. Start the engine and allow the engine to idle. 4. Depress the brake pedal firmly and maintain steady pressure on the pedal. 5. From the VSES Special Functions menu on the scan tool, select the Automated Bleed procedure. 6. Send the automated bleed command by pressing the On key on the scan tool. After initiating the automated bleed procedure, the brake pedal will drop and then pulse back up, 8 times, while the LPA is being purged of any trapped air. 7. Fill the brake master cylinder reservoir with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half full during this bleeding procedure and add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, when cap removal is necessary. 8. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 9. Install a transparent hose over the end of the bleeder valve. 10. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container. 11. Have an assistant slowly depress the brake pedal and maintain pressure on the pedal. 12. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 13. Tighten the bleeder valve when full brake pedal travel has occurred. 14. Have the assistant slowly release the brake pedal. Wait 5 seconds before proceeding to the next step. 15. Repeat steps 11-14 until all air is purged from the same wheel hydraulic circuit. 16. After all air has been purged from the right rear hydraulic circuit and the bleeder valve is tightened securely, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 17. Repeat steps 9-15 at the left rear wheel hydraulic circuit. 18. After all air has been purged from the right rear hydraulic circuit and the bleeder valve is tightened securely, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 19. Repeat steps 9-15 at the right front wheel hydraulic circuit. 20. After all air has been purged from the right rear hydraulic circuit and the bleeder valve is tightened securely, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 21. Repeat steps 9-15 at the left front wheel hydraulic circuit. 22. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container. 23. Install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 24. Install a transparent hose over the end of the bleeder valve. 25. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container. 26. Use the procedure below to purge the Medium Pressure Accumulator (MPA) of any trapped air. 26.1. With the engine still idling, select the Bleed MPA procedure from the VSES Special Functions menu. 26.2. Send the bleed MPA command by pressing the On key on the scan tool. 26.3. Open the LEFT FRONT wheel hydraulic circuit bleeder valve. Important: Ensure that you fully release the brake pedal for at least 2 seconds between pedal strokes. The amount of accumulated time between pedal strokes is calculated to deliver the most thorough bleed of the Medium Pressure Accumulator (MPA). 26.4. Depress the brake pedal as far as possible using a smooth stroke. 26.5. Release the brake pedal using a smooth stroke. 26.6. Repeat steps 26.4-26.5 until 13 complete pedal strokes have been performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8842 Important: Observe the MPA switch parameter as the pedal strokes are being performed. The MPA switch parameter should change from Uncharged to Charged several times during the first 8 or 9 strokes. After approximately 10 pedal strokes, the MPA switch parameter should remain Charged. If the parameter does not change, repeat all of step 26. 26.7. The valves within the BPMV are active for the first 13 complete pedal strokes to enable the MPA to be filled and discharged, forcing any trapped air out of the LEFT FRONT wheel hydraulic circuit bleeder valve. 26.8. Continue to depress and release the brake pedal while observing the fluid within the transparent hose. When no air is observed exiting the hydraulic system, proceed to the next step. 26.9. Depress the brake pedal and maintain pedal position. 26.10. Have an assistant tighten the bleeder valve. 26.11. Release the brake pedal. 27. Remove the scan tool from the vehicle. 28. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container. 29. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 30. If the brake pedal feels spongy, repeat this entire bleed procedure. If the brake pedal still feels spongy after repeating this procedure, inspect the brake system for external leaks. 31. Observe the brake warning indicator to determine whether or not the indicator remains illuminated. 32. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. W/O JL4 ABS Automated Bleed Procedure (w/o JL4) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: This procedure may be performed on all vehicles EXCEPT those equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. 15. Drive the vehicle to exceed 13 kPa (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8843 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Manual Hydraulic Brake System Bleeding (Manual) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder- loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely- after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely- after all air has been purged from the left rear hydraulic circuit- install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely- after all air has been purged from the right front hydraulic circuitinstall a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8844 Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Pressure Hydraulic Brake System Bleeding (Pressure) Tools Required ^ J29532 Diaphragm Type Brake Pressure Bleeder, or equivalent ^ J35589-A Brake Pressure Bleeder Adapter Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder- after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J29532, or equivalent. Add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J29532, or equivalent, to the J35589-A. 8. Charge the J29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit- install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuitinstall a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8845 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J35589-A. 23. Remove the J35589-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8846 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement Brake Caliper: Service and Repair Brake Caliper Bracket Replacement Front Brake Caliper Bracket Replacement - Front Removal Procedure Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the brake pads. 3. Remove the anti-rattle clips from the brake caliper bracket. 4. Remove the brake caliper bracket mounting bolts (2). 5. Remove the brake caliper bracket (1). 6. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 7. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8851 1. Install the brake caliper bracket (1). 2. Perform the following procedure before installing the brake caliper bracket mounting bolts. ^ Remove all traces of the original adhesive patch. ^ Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. ^ Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the caliper bracket mounting bolts (2). ^ Tighten the brake caliper bracket to knuckle bolt to 175 Nm (121 ft. lbs.) for the 15 Series. ^ Tighten the brake caliper bracket to knuckle bolts to 300 Nm (221 ft. lbs.) for 25 Series. 4. Install the anti-rattle clips to the brake caliper bracket. 5. Install the brake pads to the brake caliper bracket. ^ Install the inner pad-1 wear indicator. ^ Install the inner pad-2 wear indicators. 6. Slide the brake pads in until they contact the rotor. 7. Install the brake caliper. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 1-11 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Rear Brake Caliper Bracket Replacement - Rear Removal Procedure Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8852 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the brake pads. 3. Remove the anti-rattle clips from the brake caliper bracket. 4. Remove the brake caliper bracket mounting bolts (2). 5. Remove the brake caliper bracket (1). 6. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 7. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure 1. Install the brake caliper bracket (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8853 2. Perform the following procedure before installing the brake caliper bracket mounting bolts. ^ Remove all traces of the original adhesive patch. ^ Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. ^ Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the caliper bracket mounting bolts (2). ^ For vehicles equipped with JC5/JH5 brake systems, tighten the caliper bracket mounting bolts to 200 Nm (148 ft. lbs.). ^ For vehicles equipped with JH6 brake systems, tighten the caliper bracket mounting bolts to 165 Nm (122 ft. lbs.). 4. Install the anti-rattle clips to the brake caliper bracket. 5. Install the brake pads to the brake caliper bracket. 6. Slide the brake pads in until they contact the rotor. 7. Install the brake caliper. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 7-8 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8854 Brake Caliper: Service and Repair Brake Caliper Overhaul Front Brake Caliper Overhaul - Front Disassembly Procedure Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. 1. Remove the brake caliper from the vehicle. 2. Place a thin piece of wood in front of the piston in order to prevent damage. Remove the piston by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the piston boot. 4. Remove the piston seal. 5. Remove the brake caliper bleed screw cap. 6. Remove the brake caliper bleed screw. 7. Inspect the brake caliper bore and the piston seal groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal area, replace the brake caliper housing. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8855 8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if necessary. 9. Clean all of the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket. 10. Clean all of the parts not included in the repair kit with denatured alcohol. 11. Dry all of the parts with filtered Unlubricated compressed air. 12. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve. Assembly Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the brake caliper bleed screw. Tighten the brake caliper bleed screw to 12 Nm (106 inch lbs.). 2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seals and the brake caliper bore seal grooves with brake fluid, GM P/N 12388967 (Canadian P/N 992667). 4. Install new seals into the brake caliper bore seal grooves. 5. Ensure that the seals are not twisted. 6. Lubricate the brake caliper bores and the pistons with brake fluid, GM P/N 12388967 (Canadian P/N 992667). 7. Install the boot and piston. 7.1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. 7.2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. 7.3. Push down the piston to the bottom of the brake caliper bore. 7.4. Ensure the boot seats properly into the piston groove and into the groove in the brake caliper bore. 7.5. Repeat steps 5 and 6 for the remaining piston. 8. Install the brake caliper to the vehicle. Rear Brake Caliper Overhaul - Rear Disassembly Procedure Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. 1. Remove the brake caliper from the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8856 2. Place a thin piece of wood in front of the piston in order to prevent damage. Remove the piston by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the piston boot. 4. Remove the piston seal. 5. Remove the brake caliper bleed screw cap. 6. Remove the brake caliper bleed screw. 7. Inspect the brake caliper bore and the piston seal groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal area, replace the brake caliper housing. 8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed. 9. Clean all the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket. 10. Clean all the parts not included in the repair kit with denatured alcohol. 11. Dry all the parts with filtered Unlubricated compressed air. 12. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve. Assembly Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8857 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the brake caliper bleed screw. Tighten the brake caliper bleed screw to 12 Nm (106 inch lbs.). 2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid, GM P/N 12388967 (Canadian P/N 992667). 4. Install new the seal into the brake caliper bore seal groove. 5. Ensure that the seal is not twisted. 6. Lubricate the brake caliper bore and the piston with brake fluid, GM P/N 12388967 (Canadian P/N 992667). 7. Install the boot and the piston. 7.1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. 7.2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. 7.3. Push down the piston to the bottom of the brake caliper bore. 7.4. Ensure that the boot properly seats into the piston groove and into the groove in the brake caliper bore. 7.5. Repeat steps 5 and 6 for the remaining piston. 8. Install the brake caliper to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8858 Brake Caliper: Service and Repair Brake Caliper Replacement Front Brake Caliper Replacement - Front Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. ^ Remove the C-clamp from the caliper. 7. Clean all dirt and foreign material from the brake hose end. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. 8. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 10. Remove the brake hose from the caliper. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8859 11. Remove the 2 brake caliper mounting bolts. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result 12. Remove the brake caliper from the brake caliper mounting bracket. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the brake caliper to the brake caliper mounting bracket. 2. Install the 2 brake caliper mounting bolts. Tighten the bolts to 108 Nm (80 ft. lbs.). 3. Remove the rubber cap or plug from the exposed brake hose fitting end. Important: Install 2 New copper brake hose gaskets. 4. Assemble the 2 New copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8860 5. Install the brake hose to caliper bolt to the brake caliper. Tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Rear Brake Caliper Replacement - Rear Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level then no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level then remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. ^ Remove the C-clamp from the caliper. 7. Clean all dirt and foreign material from the brake hose end. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8861 8. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 10. Remove the caliper guide pin bolts. 11. Remove the brake caliper from the vehicle. 12. Inspect the caliper assembly. Installation Procedure Important: Use denatured alcohol to clean the outside surface of caliper boots before installing new brake pads. 1. If you are installing new brake pads use a C-clamp in order to compress the pistons to the bottom of the caliper bores. Use the old brake pad, a metal plate or a wooden block across the face of the pistons in order to protect the pistons and the caliper boots. Important: Use a small flat-bladed tool and lift the inner edge of the caliper boots next to both pistons to release any trapped air. 2. Ensure that the caliper boots are below the level of the face of both pistons. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8862 3. Install the brake caliper to the brake caliper mounting bracket. 4. Perform the following procedure before installing the caliper guide pin bolts. 4.1. Remove all traces of the original adhesive patch. 4.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 4.3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 5. Install the brake caliper mounting bolts. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the brake caliper guide pin bolts - rear 15 Series. Tighten the to 42 Nm (31 ft. lbs.). 7. Remove the rubber cap or plug from the exposed brake hose fitting end. Important: Install 2 New copper brake hose gaskets. 8. Assemble the 2 New copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 9. Connect the brake hose at the caliper by installing the brake hose to caliper bolt. Tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.). 10. Bleed the hydraulic brake system. 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. Fill the master cylinder reservoir to the proper level with clean brake fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8863 Brake Caliper: Service and Repair Disc Brake Hardware Replacement Front Disc Brake Hardware Replacement - Front Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 4. Remove the disc brake pads from the disc brake caliper mounting bracket. 5. Remove the disc brake pad retainers from the disc brake caliper mounting bracket. 6. Inspect the disc brake hardware. 7. Remove the caliper pin boots (4) from the disc brake caliper mounting bracket (3). Installation Procedure 1. Lubricate the front brake caliper bushings, bolts and seals with high temperature silicone brake lubricant. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8864 2. Install the caliper pin boots (4) to the disc brake caliper mounting bracket (3). 3. Install the disc brake pad retainers to the disc brake caliper mounting bracket. 4. Install the disc brake pads to the disc brake caliper mounting bracket. 5. Install the disc brake caliper to the caliper mounting bracket. 6. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 7. Slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 7-8 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Rear Disc Brake Replacement - Rear Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 8865 Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 3. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 4. Remove the disc brake pads from the disc brake caliper bracket. 5. Remove the disc brake pad retainers from the disc brake caliper bracket. 6. Remove the caliper pins (5) from the disc brake caliper mounting bracket (3). 7. Remove the caliper pin boots (4) from the disc brake caliper mounting bracket. 8. Inspect the disc brake hardware. Installation Procedure 1. Lubricate the brake caliper, bushings, bolts and seals with high temperature silicone brake lubricant. 2. Install the caliper pin boots (4) to the disc brake caliper mounting bracket. 3. Install the caliper pins (5) to the disc brake caliper mounting bracket (3). 4. Install the disc brake pad retainers to the disc brake caliper bracket. 5. Install the disc brake pads to the disc brake caliper bracket. 6. Install the disc brake caliper to the mounting bracket. 7. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 7-8 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic Brake System Delco Supreme 11 Brake Fluid GM Part No. 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 8872 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector from the fluid level sensor. 2. Remove the fluid level sensor (1). Use a needle nose pliers in order to compress the locking tabs at the opposite side of the master cylinder. Installation Procedure 1. Install the fluid level sensor (1) until the locking tabs snap into place. 2. Connect the electrical connector to the fluid level sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Specifications Brake Fluid Pressure Sensor/Switch: Specifications Brake Fluid Pressure Sensor (JL4) ........................................................................................................................................................... 16 Nm (12 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > MPA Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > MPA Switch > Page 8878 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Service and Repair > Brake Fluid Pressure Sensor Replacement Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Fluid Pressure Sensor Replacement Brake Fluid Pressure Sensor Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the alien bolt (2) from the Brake Pressure Modulator Valve (BPMV) mounting bracket (3) located on the sensor side. 3. Raise the BPMV to access the brake fluid pressure sensor. 4. Disconnect the electrical connector from the brake fluid pressure sensor. Important: The replacement of the old brake fluid pressure sensor must be performed quickly to reduce the amount of fluid that is lost during the procedure. 5. Use a wrench to keep the brake fluid pressure sensor collar from turning (1). Remove the brake fluid pressure sensor (2) from the BPMV. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Service and Repair > Brake Fluid Pressure Sensor Replacement > Page 8881 Notice: Refer to Fastener Notice in Service Precautions. 1. Quickly install the new brake fluid pressure sensor (2) to the BPMV as soon as the old sensor has been removed. Use a wrench to keep the brake fluid pressure sensor collar from turning (1). Tighten the brake fluid pressure sensor to 16 Nm (12 ft. lbs.). 2. Install the alien bolt (2) to the Brake Pressure Modulator Valve (BPMV) mounting bracket (3). Tighten the alien bolt to 9 Nm (7 ft. lbs.). 3. Connect the electrical connector to the brake fluid pressure sensor. 4. Lower the vehicle. 5. Check and fill the brake fluid level in the master cylinder. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Service and Repair > Brake Fluid Pressure Sensor Replacement > Page 8882 Brake Fluid Pressure Sensor/Switch: Service and Repair Pressure Accumulator Switch Replacement Pressure Accumulator Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the bolts (2) that secure the Brake Pressure Modulator Valve (BPMV) (1) to the mounting bracket (3). 3. Disconnect the electrical connector from the pressure accumulator switch. 4. Position the BPMV to be able to remove the pressure accumulator switch. 5. Remove the pressure accumulator switch from the BPMV. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Service and Repair > Brake Fluid Pressure Sensor Replacement > Page 8883 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the pressure accumulator switch to the BPMV. Tighten the pressure accumulator switch to 3 Nm (30 inch lbs.). 2. Connect the electrical connector to the pressure accumulator switch. 3. Install the Brake Pressure Modulator Valve (BPMV) (1) and the bolts (2) to the mounting bracket (3). Tighten the bolts to 9 Nm (7 ft. lbs.). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Brake Hose to Caliper Bolt, Front ............................................................................................................................................................. 40 Nm (30 ft. lbs.) Brake Hose to Caliper Bolt, Rear .............................................................................................................................................................. 40 Nm (30 ft. lbs.) Brake Pipe Fittings ................................................................................................. ................................................................................ 25 Nm (18 ft. lbs.) Hose Bracket to Frame Bolt .. .............................................................................................................................................................. . 12 Nm (106 inch lbs.) Hose Bracket to Rear Axle Bolt ........................................................................................................................................................... 12 Nm (106 inch lbs.) Hose Bracket to Anchor Plate Bolt ............................................................................................................................................................ 25 Nm (18 ft. lbs.) Hose Bracket to Knuckle Bolt .............................................................................................................................................................. 12 Nm (106 inch lbs.) Hose Bracket to Upper Control Arm Bolt................................................................................................................................................. 9 Nm (80 inch lbs.) Front Brake Lines to BPMV ..................................................................................... ................................................................................ 25 Nm (18 ft. lbs.) Master Cylinder Brake Lines to BPMV .................................................................................................................................................... 25 Nm (18 ft. lbs.) Rear Brake Line to BPMV ........................................................................................... ............................................................................ 25 Nm (18 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement Removal Procedure Caution: Refer to Brake Pipe Replacement Caution in Service Precautions. Important: Brake pipes that run parallel to each other must maintain a 6 mm (1/4 inch) clearance. 1. Disconnect the brake pipe fittings. 2. Remove the brake pipe fasteners from the vehicle. 3. Remove the brake pipe from the vehicle. Installation Procedure 1. Bend the brake pipe to achieve proper fit. 2. Install the brake pipe to the vehicle. Maintain a clearance of 19 mm (3/4 inch) for all moving or vibrating components. 3. Install the brake pipe fasteners to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 4. Connect the brake pipe fittings. ^ Tighten the brake pipe fittings to the BPMV or the wheel jounce hoses to 25 Nm (18 ft. lbs.). ^ Tighten the brake pipe fittings to the master cylinder to 25 Nm (18 ft. lbs.). ^ Bleed the hydraulic brake system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 8889 Brake Hose/Line: Service and Repair Hose Front Brake Hose Replacement - Front Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Clean all dirt and foreign material from the brake hose end and brake pipe fitting. Important: Install a rubber cap or plug to the exposed brake pipe fitting end in order to prevent brake fluid loss and contamination. 4. Use a backup wrench on the brake hose fitting end (2), disconnect the brake pipe fitting end (1) from the brake hose (2), then cap or plug the brake pipe fitting end. 5. Remove the brake hose retaining clip (3) from the brake hose mounting bracket. 6. Remove the brake hose bracket bolt from the upper control arm. 7. Remove the brake hose bracket bolt from the steering knuckle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 8890 8. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. Installation Procedure Important: Install 2 New copper brake hose gaskets. 1. Assemble the 2 New copper brake hose gaskets and the brake hose bolt to the brake hose. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the brake hose to caliper bolt-front, and 2 New washers to the brake caliper. Tighten the bolt to 40 Nm (30 ft. lbs.). Important: The brake hose must not be twisted. Make sure the brake hose is not in contact with any suspension component. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 8891 3. Install the brake hose bracket bolt and the bracket to the steering knuckle. Tighten the bolt to 9 Nm (80 inch lbs.). 4. Install the brake hose bracket bolt and the bracket to the upper control arm. Tighten the bolt to 9 Nm (80 inch lbs.). 5. Install the brake hose into the brake hose bracket. 6. Install the brake hose retaining clip (3). 7. Remove the rubber cap or plug from the brake pipe fitting end. 8. Connect the brake pipe fitting end (1) to the brake hose (2): ^ Use a backup wrench on the brake hose fitting end (2). ^ Do not bend the mounting bracket or the brake pipe. Tighten the brake pipe fitting end (1) to 25 Nm (18 ft. lbs.). 9. Bleed the hydraulic brake system. 10. Install the tire and wheel assembly. Important: Ensure that the brake hose does not make contact with any part of the suspension or the tire/wheel assembly. Check the brake hose in extreme right and left turn conditions. If the brake hose makes contact remove the brake hose and correct the condition. 11. Lower the vehicle. Rear Caliper Brake Hose Replacement - Rear (Caliper) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Clean all dirt and foreign material from the brake hose end and brake pipe fitting. Important: Install a rubber cap or plug to the exposed brake pipe fitting end in order to prevent brake fluid loss and contamination. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 8892 4. Use a backup wrench on the brake hose fitting end (1), disconnect the brake pipe fitting end (2) from the brake hose (1) then cap or plug the brake pipe fitting end. 5. Remove the brake hose retaining clip (3) from the brake hose mounting bracket. 6. Remove the brake hose (1) from the mounting bracket. 7. Remove the brake hose to caliper bolt from the brake caliper. 8. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. Installation Procedure Important: Install 2 New copper brake hose gaskets. 1. Assemble the 2 New copper brake hose gaskets and the brake hose bolt to the brake hose. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 8893 2. Install the brake hose to caliper bolt-rear, and 2 New washers to the brake caliper. Tighten the bolt to 40 Nm (30 ft. lbs.). Important: The brake hose must not be twisted. Make sure the brake hose is not in contact with any suspension component. 3. Install the brake hose (1) into the mounting bracket. 4. Install the brake hose retaining clip (3). 5. Remove the rubber cap or plug from the exposed brake pipe fitting end. 6. Connect the brake pipe fitting end (2) to the brake hose (1): ^ Use a backup wrench on the brake hose fitting end (1). ^ Do not bend the mounting bracket or the brake pipe. Tighten the brake pipe fitting end (2) to 25 Nm (18 ft. lbs.). 7. Bleed the hydraulic brake system. 8. Install the tire and wheel assembly. Important: Ensure that the brake hose does not make contact with any part of the suspension or the tire/wheel assembly. If the brake hose makes contact remove the brake hose and correct the condition. 9. Lower the vehicle. Rear Jounce Brake Hose Replacement - Rear (Jounce) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Clean all dirt and foreign material from the brake hose and brake pipe fittings. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 8894 3. Use a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose, then cap or plug the brake pipe fitting end. 4. Remove the brake hose retaining clip from the hose mounting bracket. 5. Remove the jounce hose from the bracket. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. 6. Disconnect the 2 rear brake pipes from the junction block on the rear axle and cap or plug the brake pipe fitting ends. 7. Remove the junction block retaining bolt from the axle. 8. Remove the brake hose from the vehicle. Installation Procedure 1. Install the rear brake hose Notice: Refer to Fastener Notice in Service Precautions. 2. Install the junction block retaining bolt to the axle. Tighten the bolt to 12 Nm (106 inch lbs.). 3. Remove the caps or plugs from the rear brake pipes and connect the pipes to the junction block on the axle. Tighten the fitting to 25 Nm (18 ft. lbs.). Important: The hose must not be twisted. Make sure the hose is not in contact with any suspension component. 4. With the weight of the vehicle on the suspension, install the brake hose into the bracket. 5. Install the jounce hose retaining clip. 6. Remove the rubber cap or plug from the exposed brake pipe fitting end. 7. Connect the brake pipe fitting to the brake hose: ^ Use a backup wrench on the hose fitting. ^ Do not bend the bracket or the pipe. Tighten the fitting to 25 Nm (18 ft. lbs.). 8. Ensure that the hose does not make contact with any part of the suspension. If the hose makes contact, remove the hose and correct the condition. 9. Bleed the hydraulic brake system. 10. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake Pressure Modulator Bleeder Valves ............................................................................................................................................. 9 Nm (80 inch lbs.) EHCU Bracket to Frame Bolt ............................................................................................... .................................................................... 25 Nm (18 ft. lbs.) EHCU to Bracket Allen Bolt .............. .......................................................................................................................................................... 9 Nm (7 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > W/ JL4 Hydraulic Control Assembly - Antilock Brakes: Service and Repair W/ JL4 Brake Pressure Modulator Valve (BPMV) Replacement (w/ JL4) Removal Procedure Important: The area around the Electric Hydraulic Control Unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled ABS components. 1. Thoroughly wash all contaminants from around the EHCU. 2. Disconnect the 2 electrical harness connectors from the Electronic Brake Control Module (EBCM) (1). 3. Disconnect the electrical connector from the pressure accumulator switch. 4. Disconnect the electrical connector from the brake fluid pressure sensor. Important: Make sure that brake lines are tagged and kept in order for proper reassembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > W/ JL4 > Page 8900 5. Disconnect the brake lines from the Brake Pressure Modulator Valve (BPMV) (2). 6. Remove the bolts (4) securing the EHCU mounting bracket (3) to the frame rail (5). 7. Remove the EHCU from the vehicle. 8. Remove the bolts (4) securing the BPMV (1) to the EHCU mounting bracket (3). 9. Remove the 4 T-25 torx bolts from the EBCM (2). 10. Remove the EBCM (2) from the BPMV (1). Removal may require a light amount of force. 11. Remove the accumulator switch. 12. Remove the brake fluid sensor (2). Important: Do not reuse the EBCM mounting bolts. Always install new bolts. 13. Clean the EBCM to BPMV mounting surfaces with a clean cloth. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > W/ JL4 > Page 8901 Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the pressure accumulator switch to the BPMV. Tighten the switch to 3 Nm (30 inch lbs.). 2. Install the brake fluid pressure sensor (2) using a backup wrench to keep the brake fluid pressure sensor collar (1) from turning. Tighten the sensor to 16 Nm (12 ft. lbs.). Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 3. Install the EBCM (2) onto BPMV (1). 4. Install the four EBCM bolts. Important: Do not reuse the old mounting bolts. Always install new EBCM bolts with the new BPMV. Tighten the bolts to 5 Nm (39 inch lbs.) in an X-pattern. 5. Connect the brake fluid pressure sensor and pressure accumulator switch electrical harnesses. 6. Install the BPMV (1) to EHCU bracket (3). 7. Install the BPMV to bracket retaining bolts (4). Tighten the bolts to 9 Nm (7 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > W/ JL4 > Page 8902 8. Install the EHCU to the vehicle frame (5). 9. Install the EHCU bracket bolts. Tighten the EHCU bracket bolts (4) to 25 Nm (18 ft. lbs.). 10. Connect the 2 electrical harness connectors to the EBCM (1). Important: The brake pipes are held in place by a plastic bracket mounted to the frame. Make sure that the brake pipes stay in the correct place for proper reassembly. 11. Install the brake pipes to the BPMV (2). Tighten the brake pipe fittings to 25 Nm (18 ft. lbs.). 12. Bleed the brake system. 13. Bleed the brake system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > W/ JL4 > Page 8903 Hydraulic Control Assembly - Antilock Brakes: Service and Repair W/O JL4 Brake Pressure Modulator Valve (BPMV) Replacement (w/o JL4) Removal Procedure Important: The area around the electric hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled ABS components. 1. Thoroughly wash all contaminants from around the EHCU. 2. Disconnect the 3 electrical harness connectors from the electronic brake control module (EBCM) (1). Important: Make sure that brake lines are tagged and kept in order for proper reassembly. 3. Disconnect the brake lines from the brake pressure modulator valve (BPMV) (2). 4. Remove the bolts (4) securing the EHCU mounting bracket (3) to the frame rail (5). 5. Remove the EHCU from the vehicle. 6. Remove the bolts (4) securing the BPMV (1) to the EHCU mounting bracket (3). 7. Disconnect the 2 way ABS pump motor connector. 8. Remove the 4 T-25 TORX bolts from the EBCM (2). 9. Remove the EBCM (2) from the BPMV (1). Removal may require a light amount of force. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. 10. Clean the EBCM to BPMV mounting surfaces with a clean cloth. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > W/ JL4 > Page 8904 Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install the EBCM (2) onto BPMV (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four EBCM bolts. Important: Do not reuse the old mounting bolts. Always install new EBCM bolts with the new BPMV. Tighten the 4 bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2 way ABS pump motor connector to the EBCM. 4. Install the BPMV (1) to EHCU bracket (3). 5. Install the BPMV (1) to bracket retaining bolts (4). Tighten the bolts to 9 Nm (7 ft. lbs.). 6. Install the EHCU to the vehicle frame (5). Tighten the three EHCU bracket bolts (4) to 25 Nm (18 ft. lbs.). 7. Connect the 2 electrical harness connectors to the EBCM (1). Important: The brake pipes are held in place by a plastic bracket mounted to the frame. Make sure that the brake pipes stay in the correct place for proper reassembly. 8. Install the 5 brake pipes to the BPMV (6). Tighten the brake pipe fittings to 25 Nm (18 ft. lbs.). 9. Bleed the brake system. 10. Bleed the brake system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Master Cylinder Mounting Nuts ........................................................................................................... .................................................... 36 Nm (27 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul Brake Master Cylinder: Service and Repair Master Cylinder Overhaul Master Cylinder Overhaul Disassembly Procedure 1. Remove the brake master cylinder from the vehicle. 2. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 3. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 4. Remove the reservoir cap and diaphragm from the reservoir. 5. Inspect the reservoir cap and diaphragm for the following conditions. If any of these conditions are present, replace the affected components. ^ Cuts or cracks ^ Nicks or deformation 6. Remove the master cylinder reservoir from the master cylinder. 7. Using a smooth, round-ended tool, depress the primary piston (2) and remove the piston retainer. 8. Remove the primary piston assembly from the cylinder bore. 9. Plug the cylinder inlet ports and the rear outlet port. Apply low pressure, non-lubricated, filtered air into the front outlet port, in order the remove the secondary piston (1) with the primary (6) and secondary (5) seals, and the return spring. 10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from the secondary piston. Assembly Procedure Important: Do not use abrasives to clean the brake master cylinder bore. 1. Clean the interior and exterior of the master cylinder, the secondary piston (1), and the return spring in denatured alcohol, or equivalent. 2. Inspect the master cylinder bore, inlet and outlet ports, the secondary piston (1), and the return spring for cracks, scoring, pitting, and/or corrosion. Replace the master cylinder if any of these conditions exist. 3. Dry the master cylinder and the individual components with non-lubricated, filtered air. 4. Lubricate the master cylinder bore, the secondary piston (1), the return spring, and all of the individual overhaul components with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Assemble the lubricated, new primary seal (6) and retainer and new secondary seal (5) onto the secondary piston. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 8910 6. Install the lubricated return spring and secondary piston assembly (1) into the cylinder bore. 7. Install the lubricated, new primary piston assembly (2) into the cylinder bore. 8. Using a smooth, round-ended tool, depress the primary piston (2) and install the new piston retainer. 9. Install the master cylinder reservoir to the master cylinder. 10. Install the reservoir cap and diaphragm to the reservoir. 11. Install the master cylinder to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 8911 Brake Master Cylinder: Service and Repair Master Cylinder Replacement Vacuum Boost Master Cylinder Replacement (Vacuum Boost) Removal Procedure 1. Apply the park brake and block the wheels. 2. Disconnect the electrical connector from the brake fluid level sensor. 3. Disconnect the brake pipes from the master cylinder. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. 4. Plug the open brake pipe ends. 5. Remove the master cylinder mounting nuts. 6. Remove the master cylinder from the vehicle. 7. Remove the master cylinder reservoir. Installation Procedure 1. Install the master cylinder reservoir. 2. Bench bleed the master cylinder. 3. Install the master cylinder to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 8912 4. Install the master cylinder mounting nuts. Tighten the nuts to 36 Nm (27 ft. lbs.). 5. Remove the rubber cap or plug from the exposed brake pipe fitting ends. 6. Connect the brake pipes. Tighten the fittings to 25 Nm (18 ft. lbs.). 7. Connect the electrical connector to the brake fluid level sensor. 8. Bleed the hydraulic brake system. 9. Release the park brake and unblock the wheels. Hydraulic Boost Master Cylinder Replacement (Hydraulic Boost) Removal Procedure 1. Apply the park brake and block the wheels. 2. Disconnect the electrical connector from the brake fluid level sensor. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 8913 3. Plug the open brake pipe ends. 4. Remove the master cylinder mounting nuts. 5. Remove the master cylinder from the vehicle. 6. Remove the master cylinder reservoir. Installation Procedure 1. Install the master cylinder reservoir. 2. Bench bleed the master cylinder. 3. Install the master cylinder to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the master cylinder mounting nuts. Tighten the nuts to 36 Nm (27 ft. lbs.). 5. Remove the rubber cap or plug from the exposed brake pipe fitting ends. 6. Connect the brake pipes. Tighten the pipe fittings to 25 Nm (18 ft. lbs.). 7. Connect the electrical connector to the brake fluid level sensor. 8. Bleed the hydraulic brake system. 9. Release the park brake and unblock the wheels. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 8914 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement Master Cylinder Reservoir Replacement Removal Procedure 1. Apply the park brake and block the wheels. 2. Remove the master cylinder. 3. Drain the master cylinder reservoir. 4. Secure the master cylinder in a vise. Do not clamp the master cylinder body, secure only at the flange. 5. Remove the brake fluid level sensor by carefully depressing the retaining tabs and pushing the sensor through the reservoir. 6. Carefully remove the reservoir retaining pins. 7. Remove the reservoir from the master cylinder by pulling the reservoir straight up and away from the cylinder. 8. Remove the seals from the master cylinder. Installation Procedure 1. Inspect the reservoir for cracks or deformation. If found, replace the reservoir. 2. Clean the reservoir with denatured alcohol, or equivalent. 3. Dry the reservoir with non-lubricated, filtered air. 4. Lubricate the new seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid, from a clean, sealed brake fluid container. 5. Install the lubricated seals, make sure they are fully seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 8915 6. Install the reservoir to the master cylinder by pressing the reservoir straight down on the master cylinder until the pin holes are aligned. 7. Carefully install the reservoir retaining pins to secure the reservoir. 8. Place the brake fluid level sensor into the reservoir, press into place to secure the sensor retaining tabs. 9. Remove the master cylinder from the vice. 10. Install the master cylinder. 11. Release the park brake. 12. Bleed the hydraulic brake system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 8916 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Service and Repair Parking Brake Actuator: Service and Repair Park Brake Actuator Replacement Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. 4. Relieve the tension from the park brake cables by loosening the nut at the equalizer. 5. Remove the rear park brake cable from the park brake actuator lever. 6. Remove the park brake cable from the mounting bracket by depressing the locking tabs. 7. Remove the rotor. 8. Remove the axle shaft. 9. Remove the park brake shoe. 10. Remove the backing plate bolts. 11. Remove the park brake actuator lever housing from the backing plate. Installation Procedure 1. Install the park brake actuator lever housing to the backing plate. 2. Perform the following procedure before installing the backing plate bolts. 2.1. Remove all traces of the original adhesive patch. 2.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 2.3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the backing plate bolts. Tighten the backing plate bolts to 135 Nm (100 ft. lbs.). 4. Install the park brake shoe. 5. Install the axle shaft. 6. Adjust the park brake shoe. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Service and Repair > Page 8925 7. Install the rotor. 8. Install the park brake cable to the mounting bracket until the locking tabs snap into place. 9. Install the rear park brake cable to the park brake actuator lever. 10. Tighten the nut to the intermediate cable at the equalizer. Tighten the nut to 3.5 Nm (31 inch lbs.). 11. Install the tire and wheel assembly. 12. Remove the safety stands. 13. Lower vehicle. 14. Adjust park brake cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications Park Brake Cable Guide to Frame Bolt ............................................................................................................................................... 12 Nm (106 inch lbs.) Park Brake Cable to Rear Axle Clip Bolt ................................................................................................................................................. 25 Nm (18 ft. lbs.) Park Brake Cable to Shock Absorber Bracket Bolt .................................................................................................................................. 25 Nm (18 ft. lbs.) Cable Support Bracket Nuts ........................................................................................................ ............................................................. 85 Nm (64 ft. lbs.) Intermediate Cable Threaded Rod Nut ................................................................................................................................................. 3.5 Nm (31 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications > Page 8929 Parking Brake Cable: Adjustments Disabling the Park Brake Cable Automatic Adjuster Before any components of the parking brake system are serviced, the following procedure must be followed. Two technicians are required to perform this procedure: one inside the vehicle and one outside the vehicle. 1. Raise and support the vehicle. 2. Hold the pedal in the FULL upward position. 3. Pull rearward on the front park brake cable until the pedal drum (2) reaches its full reset position. 4. Insert a scribe or the shaft of a thin screwdriver (1) on an upward angle through the hole in the front of the pedal assembly, past the retracted pedal drum, and into the hole in the back of the pedal assembly (3). 5. Slowly release the cable. 6. Remove the component that requires service. Enabling the Park Brake Cable Automatic Adjuster If the park brake automatic adjuster has been disabled, the following two person procedure must be performed. 1. Hold the park brake pedal in the FULL upward position. 2. Pull rearward on the front park brake cable until the tension is released from the scribe or nail (1) installed through the holes in the pedal assembly. 3. Remove the scribe or screwdriver (1). 4. Slowly release the park brake cable until it returns to its original position. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications > Page 8930 5. Release the park brake pedal. 6. Lower the vehicle. 7. Apply and release the park brake pedal to ensure that there is no binding or sticking. Please refer to Parking Brake Pedal Adjustments. See: Parking Brake Pedal/Adjustments Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement Parking Brake Cable: Service and Repair Park Brake Cable Replacement Intermediate Park Brake Cable Replacement - Intermediate Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the nut from the threaded end of the intermediate cable. 4. Disconnect the equalizer from the rear park brake cables. 5. Disconnect the intermediate cable from the front cable. 6. Remove the intermediate cable. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 8933 1. Install the intermediate cable. 2. Connect the intermediate cable to the front cable. 3. Connect the equalizer to the rear park brake cables. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the nut to the threaded end of the intermediate cable. Tighten the nut to 3.5 Nm (31 inch lbs.). 5. Remove the safety stands. 6. Lower the vehicle. 7. Adjust the park brake system. Front Park Brake Cable Replacement - Front Removal Procedure 1. Release the park brake. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 8934 2. Remove the park brake pedal. 3. Roll the carpet back to access cable grommet. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Disengage the grommet and the cable from the floor pan. 6. Disconnect the front cable from the intermediate cable. 7. Remove the cable from the body mount by depressing the retaining tabs. 8. Remove the cable. Installation Procedure 1. Install the cable. 2. Snap the retainer tabs into the body mount. 3. Connect the front cable to the intermediate cable. 4. Route the cable in through the floor pan and engage the grommet. 5. Remove the safety stands. 6. Lower the vehicle. 7. Roll the carpet into place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 8935 8. Install the park brake pedal. 9. Adjust the park brake system. Left Rear (Without RPO NYS) Park Brake Cable Replacement - Left Rear (without RPO NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Relieve the tension on the park brake cables by loosening the nut at the equalizer. 4. Disconnect the cable at the equalizer. 5. Remove the cable from the mounting bracket by depressing the locking tabs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 8936 6. Remove the cable at the shock absorber bracket by removing the bolt. 7. Remove the cable from the lever, all except 15 series utilities. 8. Remove the cable from the backing plate by depressing the locking tabs. 9. Remove the cable. 10. Remove the cable from the lever, 15 series utilities. 11. Remove the cable from the backing plate by depressing the locking tabs. 12. Remove the cable. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 8937 1. Install the cable taking care to correctly route the cable through the guides and the body mounts. 2. Install the cable to the backing plate by pressing the cable into place until locking tabs snap into place, 15 series utilities. 3. Install the cable to the lever. 4. Install the cable taking care to correctly route the cable through the guides and the body mounts. 5. Install the cable to the backing plate by pressing the cable into place until locking tabs snap into place, all except 15 series utilities. 6. Install the cable to the lever. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the cable at the shock absorber bracket and install the bolt. Tighten the bolt to 25 Nm (18 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 8938 8. Install the cable to the mounting bracket until the locking tabs snap into place. 9. Connect cable end to the equalizer. 10. Tighten the nut to the intermediate cable at the equalizer. Tighten the nut to 3.5 Nm (31 inch lbs.). 11. Remove the safety stands. 12. Lower the vehicle. 13. Adjust the park brake cable. Right Rear (Without/RPO NYS) Park Brake Cable Replacement - Right Rear (without/RPO NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Relieve the tension on the cable by loosening the nut at the equalizer. 4. Disconnect the cable from the equalizer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 8939 5. Remove the bolt from the rear axle clip. 6. Remove the cable from the differential clip. 7. Remove the cable from the mounting bracket by depressing the locking tabs. 8. Remove the cable from the left and right side cable guides, 15 series utilities. 9. Remove the cable from the track bar clips. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 8940 10. Remove the cable from the lever, all except 15 series utilities. 11. Remove the cable from the backing plate by depressing the locking tabs. 12. Remove the cable from the retaining bracket. 13. Remove the cable. 14. Remove the cable from the lever, 15 series utilities. 15. Remove the cable from the backing plate by depressing the locking tabs. 16. Remove the cable from the retaining bracket. 17. Remove the cable. Installation Procedure 1. Install the cable taking care to correctly route the cable through the guides and the body mounts. 2. Install the cable to the backing plate by pressing the cable into place until locking tabs snap into place, 15 series utilities. 3. Attach the cable to the lever. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 8941 4. Install the cable taking care to correctly route the cable through the guides and the body mounts. 5. Install the cable to the backing plate by pressing the cable into place until locking tabs snap into place, all except 15 series utilities. 6. Attach the cable to the lever. 7. Install the cable to the track bar and secure with the clips. Verify that the clips are installed between the locators on the track bar, 15 series utilities. 8. Install the cable to the right and left side guides. 9. Install the cable to the mounting bracket until the locking tabs snap into place. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 8942 10. Bolt the cable to the differential clips. Tighten the bolt to 25 Nm (18 ft. lbs.). Important: After installing the cable to the rear axle holding clip, verify that clip is securely retaining the cable. If not, crimp the clip by hand taking care not to pinch or kink the cable. 11. Install the cable to the differential clip. 12. Connect the cable to the equalizer. 13. Tighten the nut to the intermediate cable at the equalizer. Tighten the nut to 3.5 Nm (31 inch lbs.). 14. Remove the safety stands. 15. Lower the vehicle. 16. Adjust the park brake cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 8943 Parking Brake Cable: Service and Repair Park Brake Cable Guide Replacement Park Brake Cable Guide Replacement Removal Procedure 1. Release the parking brake. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the park brake cable guide bolt from the frame. 4. Remove the park brake cable guide. 5. Remove the park brake guide from the park brake cable. Installation Procedure 1. Install the park brake cable guide to the park brake cable. 2. Install the park brake cable guide. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the park brake cable guide bolt to the frame. Tighten the bolt to 12 Nm (106 inch lbs.). 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 8944 Parking Brake Cable: Service and Repair Park Brake Cable Mounting Bracket Replacement Park Brake Cable Mounting Bracket Replacement Removal Procedure 1. Release the parking brake. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Release the tension on the cables by loosening the nut at the equalizer. 4. Disconnect the rear cables from the equalizer. 5. Remove the rear cables from the mounting bracket by depressing the retaining tabs and pulling rearward. 6. Remove the cable support bracket nuts. 7. Remove the cable support bracket. Installation Procedure 1. Install the cable support bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the cable support bracket nuts. Tighten the support bracket nuts to 85 Nm (64 ft. lbs.). 3. Install the rear cables to the mounting bracket by inserting the cable till all the retaining tabs snap into place. 4. Connect the rear cables to the equalizer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 8945 5. Tighten the nut to the intermediate cable at the equalizer. Tighten the nut to 3.5 Nm (31 inch lbs.). 6. Remove the safety stands. 7. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 8946 Parking Brake Cable: Service and Repair Park Brake Cable Equalizer Replacement Park Brake Cable Equalizer Replacement Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the nut from the threaded end of the intermediate cable. 4. Disconnect the equalizer from the rear park brake cables. Installation Procedure 1. Connect the equalizer to the rear park brake cables. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the nut to the threaded end of the intermediate cable. Tighten the nut to 3.5 Nm (31 inch lbs.). 3. Remove the safety stands. 4. Lower the vehicle. 5. Adjust the park brake system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications Parking Brake Lever: Specifications Park Brake Lever Mounting Bolts ............................................................................................................................................................ 25 Nm (18 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Adjustments Parking Brake Pedal: Adjustments Park Brake Pedal Adjustment Important: Before you adjust the park brake, verify that the park brake shoes are adjusted to provide a clearance of 0.6604 mm (0.026 inch). 1. Verify that the self adjuster lock-out pin has been removed, located in parking brake pedal assembly, no image location provided. (Editor's note: If there is no self-adjuster lockout pin found, as a possible alternative procedure, please refer to Disabling/Enabling the Park Brake Cable Automatic Adjuster procedure under Parking Brake Cable Adjustments.) See: Parking Brake Cable/Adjustments 2. Fully apply and release the park brake pedal 3 times. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Park Brake Pedal Assembly Replacement Parking Brake Pedal: Service and Repair Park Brake Pedal Assembly Replacement Park Brake Pedal Assembly Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Relieve the tension from the park brake cables by loosening the nut at the equalizer. 4. Remove the safety stands. 5. Lower the vehicle. 6. Remove the left side hinge pillar panel. 7. Disconnect the park brake warning lamp connection. 8. Remove the MID-Bussed Electrical Center bracket. 9. Disconnect the park brake release cable from the park brake lever. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Park Brake Pedal Assembly Replacement > Page 8955 10. Remove the park brake lever mounting nuts. 11. Disconnect the front park brake cable from the park brake lever. 12. Remove the park brake lever. Installation Procedure 1. Connect the front park brake cable to the park brake lever. 2. Install the park brake lever. 3. Install the MID-Bussed Electrical Center bracket. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the park brake lever mounting nuts. Tighten the nuts to 25 Nm (18 ft. lbs.). 5. Raise the vehicle. 6. Support the vehicle with safety stands. 7. Tighten the nut to the intermediate cable at the equalizer. Tighten the nut to 3.5 Nm (31 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Park Brake Pedal Assembly Replacement > Page 8956 8. Remove the safety stands. 9. Lower the vehicle. 10. Connect the park brake release cable to the park brake lever. 11. Connect the park brake warning lamp connector. 12. Install the left side hinge pillar panel. 13. Install the left side kick panel. 14. Connect the negative battery cable. Tighten the negative battery cable bolt to 17 Nm (13 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Park Brake Pedal Assembly Replacement > Page 8957 Parking Brake Pedal: Service and Repair Park Brake Release Handle Assembly Replacement Park Brake Release Handle Assembly Replacement Removal Procedure 1. Remove the park brake release lever mounting bolt. 2. Remove the park brake release lever handle from the knee bolster. Installation Procedure 1. Install the park brake release lever handle to the knee bolster. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake release lever mounting bolt. Tighten to 25 Nm (18 ft. lbs.). 3. Connect the park brake release cable to the lever. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-26-002A > Feb > 03 > Brakes - Scraping Noises From Rear of Vehicle Parking Brake Shoe: Customer Interest Brakes - Scraping Noises From Rear of Vehicle File In Section: 05 - Brakes Bulletin No.: 02-05-26-002A Date: February, 2003 TECHNICAL Subject: Scraping Noise From Rear Of Vehicle (Replace Parking Brake Shoe Kit and Clean Drum In Hat Rotor) Models: 2002-2003 Cadillac Escalade, Escalade EXT 1999-2003 Chevrolet Silverado 1500 Series Pickups 2000-2003 Chevrolet Suburban, Tahoe 1500 Series Models 2002-2003 Chevrolet Avalanche 1500 Series Models 1999-2003 GMC Sierra 1500 Series Pickups 2000-2003 GMC Yukon, Yukon XL 1500 Series Models This bulletin is being revised to add Suburban and Yukon XL models. Please discard Corporate Bulletin Number 02-05-26-002 (Section 05 - Brakes). Condition Some customers may comment on a scraping noise from the rear of the vehicle while driving. The noise may be intermittent. Cause Condition may due to the parking brake shoe contacting the drum in hat rotor without the parking brake being applied, causing premature wear on the shoe lining. Correction Replace the parking brake shoe and install a new designed spring clip retainer. Follow the service procedure below to correct this condition. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Information (SI Document ID # 639546). 2. Remove the tire and the wheel. Refer to Tire and Wheel Removal and Installation in the Tires and Wheels sub-section of the Service Information (SI Document ID # 656965). 3. Relieve the tension on the park brake cables by loosening the nut at the equalizer. 4. Mark the relationship of the rotor to the hub. 5. Remove the brake caliper bracket mounting bolts. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 6. Remove the brake caliper and brake caliper bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 7. Remove the rotor retaining push nuts from the wheel studs (if applicable). Notice: DO NOT use a hammer to remove the rotor from the hub; it may cause damage to the rotor. Important: The rotor may not be easily removed from the hub due to a rust build up on the outside edge of the drum and hat portion of the rotor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-26-002A > Feb > 03 > Brakes - Scraping Noises From Rear of Vehicle > Page 8966 8. Remove the rotor from the hub. If the rotor cannot be removed from the hub by pulling on the rotor, use J 46277 rotor removal tool. Notice: Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface, it may damage the rotor surface. 9. Using removal tool J 46277 on slide hammer J 6125B, remove the rotor by placing removal tool J 46277 in the vent section of the rotor at the twelve, three, six and nine o'clock positions, not necessarily in that order. 10. Clean the rust ridge from the drum portion of the rotor using a grinding stone and rotor resurfacing kit J 41013. 11. Remove the spring clip bolt (3) and retainer (2) and discard. Important: Minimum thickness of the parking brake shoe lining in any given spot is 1.5 mm (0.06 in). 12. Measure the parking brake shoe thickness in multiple spots. Replace the parking brake shoe if the thickness is less than 1.5 mm (0.06 in). Continue with Step 14. 13. If the parking brake shoe lining is greater than 1.5 mm (0.06 in), continue with Step 19. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-26-002A > Feb > 03 > Brakes - Scraping Noises From Rear of Vehicle > Page 8967 14. Rotate the parking brake shoe (1) out from the bottom and pull it out of the adjuster. Discard the shoe. 15. Remove the park brake shoe assembly from the vehicle by placing one of the open ends of the shoe over the axle flange and rotate the shoe until it has cleared the flange. 16. Turn the adjustment screw (1) to the fully home position in the notched adjustment nut. 17. Install the new park brake shoe assembly (1) from the parking brake shoe kit, P/N 88982875, to the vehicle by placing one of the open ends of the shoe over the axle flange and rotating the shoe until it is behind the flange. 18. Slide the shoe into the adjuster and position the shoe to the backing plate. Install the retaining spring clip (2) and bolt (3) from the parking brake shoe kit, P/N 88982875. If using parking brake service kit 88982875, SKIP Step 19. 19. Replace the retaining spring clip (2) and bolt (3) from the parking brake retaining spring clip kit, P/N 88982879. Tighten Tighten the bolt (3) to 5 N.m (44 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-26-002A > Feb > 03 > Brakes - Scraping Noises From Rear of Vehicle > Page 8968 20. Set the J 21177-A so that it contacts the inside diameter of the rotor. 21. Position the J 21177-A over the shoe and the lining at the widest point. Important: ^ The parking brake adjustment screw threads should not exceed 5 mm (0.2 in) of exposed thread. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-26-002A > Feb > 03 > Brakes - Scraping Noises From Rear of Vehicle > Page 8969 ^ The clearance between the park brake shoe and the rotor is 0.6604 mm (0.026 in). 22. The parking brake adjustment screw threads should not exceed 5 mm (0.2 inch) of exposed thread. Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange with the J 42450 hub cleaning kit. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. 23. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange. 24. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 25. Align the mark on the rotor with the mark on the hub and install the rotor by slowly turning the rotor while pushing the rotor towards the axle. 26. Install the caliper and the bracket as an assembly to the vehicle. 27. Perform the following procedure before installing the caliper bracket mounting bolts. ^ Remove all traces of the original adhesive. ^ Clean the threads of the bolt with brake parts cleaner, P/N 12346139 (Canadian P/N 10953463), and allow to dry. ^ Apply threadlocker, GM P/N 12345493 (Canadian P/N 10953488), or Red LOCTITE(TM) # 272, to the threads of the bolt. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 28. Install the caliper bracket mounting bolts. Tighten Tighten the brake caliper bracket mounting bolts to 175 N.m (129 lb ft). 29. Repeat this procedure on the other side of the vehicle. 30. Tighten the nut to the intermediate cable at the equalizer. Tighten Tighten the nut to 3.5 N.m (31 lb in). 31. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in the Tires and Wheels sub-section of the Service Information (SI Document ID # 656965). 32. Lower the vehicle. 33. Verify that the self adjuster lock-out pin has been removed. 34. Fully apply and release the park brake pedal three times. Parts Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-26-002A > Feb > 03 > Brakes - Scraping Noises From Rear of Vehicle > Page 8970 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 02-05-26-001C > Jan > 05 > Brakes - Park Brake Shoe Retaining Clip Kit Parking Brake Shoe: All Technical Service Bulletins Brakes - Park Brake Shoe Retaining Clip Kit Bulletin No.: 02-05-26-001C Date: January 19, 2005 INFORMATION Subject: Rear Parking Brake Shoe Retaining Spring Clip Service Kit for Drum-in-Hat (DIH) Equipped Vehicles Models: 2004-2005 Buick Rainier 2002-2005 Cadillac Escalade Models 2002-2005 Chevrolet Avalanche 1998-2005 Chevrolet Blazer 1999-2005 Chevrolet Silverado Models 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet SSR, TrailBlazer Models 2003-2005 Chevrolet Astro, Express 1998-2005 GMC Jimmy 1999-2005 GMC Sierra Models 2000-2005 GMC Yukon Models 2002-2005 GMC Envoy Models 2003-2005 GMC Safari, Savana 1998-2004 Oldsmobile Bravada This Bulletin ONLY applies to 1500 series vehicles with four wheel disc brakes. Supercede: This bulletin is being revised to include additional models and clarify parts usage information. Please discard Corporate Bulletin Number 02-05-26-001B (Section 05 - Brakes). A rear parking brake retaining spring clip kit has been released for service. This kit consists of two parking brake hold down spring clips (2) and bolts (3). Note: Use J 46277 Rotor Removal Tool with J 6125-B Slide Hammer to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface, it may damage the rotor surface. During rear brake rotor removal, it is possible to damage the parking brake shoe retaining spring clip. Order this new kit when replacement of the clips is required but the parking brake shoes do not require replacement. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 02-05-26-001C > Jan > 05 > Brakes - Park Brake Shoe Retaining Clip Kit > Page 8976 Important: The spring clip kits mentioned in this bulletin do not address any parking brake concerns. Refer to the Parking Brakes sub-section of the Service Manual for any diagnostic information. Parts Information Parts are currently available from GMSPO. Warranty Information When removal of the rear brake rotors results in damage to the spring clips on vehicles under warranty, use the labor operation shown in conjunction with one of the kit part numbers listed above. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 02-05-26-001C > Jan > 05 > Brakes - Park Brake Shoe Retaining Clip Kit > Page 8977 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 02-05-26-002A > Feb > 03 > Brakes - Scraping Noises From Rear of Vehicle Parking Brake Shoe: All Technical Service Bulletins Brakes - Scraping Noises From Rear of Vehicle File In Section: 05 - Brakes Bulletin No.: 02-05-26-002A Date: February, 2003 TECHNICAL Subject: Scraping Noise From Rear Of Vehicle (Replace Parking Brake Shoe Kit and Clean Drum In Hat Rotor) Models: 2002-2003 Cadillac Escalade, Escalade EXT 1999-2003 Chevrolet Silverado 1500 Series Pickups 2000-2003 Chevrolet Suburban, Tahoe 1500 Series Models 2002-2003 Chevrolet Avalanche 1500 Series Models 1999-2003 GMC Sierra 1500 Series Pickups 2000-2003 GMC Yukon, Yukon XL 1500 Series Models This bulletin is being revised to add Suburban and Yukon XL models. Please discard Corporate Bulletin Number 02-05-26-002 (Section 05 - Brakes). Condition Some customers may comment on a scraping noise from the rear of the vehicle while driving. The noise may be intermittent. Cause Condition may due to the parking brake shoe contacting the drum in hat rotor without the parking brake being applied, causing premature wear on the shoe lining. Correction Replace the parking brake shoe and install a new designed spring clip retainer. Follow the service procedure below to correct this condition. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Information (SI Document ID # 639546). 2. Remove the tire and the wheel. Refer to Tire and Wheel Removal and Installation in the Tires and Wheels sub-section of the Service Information (SI Document ID # 656965). 3. Relieve the tension on the park brake cables by loosening the nut at the equalizer. 4. Mark the relationship of the rotor to the hub. 5. Remove the brake caliper bracket mounting bolts. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 6. Remove the brake caliper and brake caliper bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 7. Remove the rotor retaining push nuts from the wheel studs (if applicable). Notice: DO NOT use a hammer to remove the rotor from the hub; it may cause damage to the rotor. Important: The rotor may not be easily removed from the hub due to a rust build up on the outside edge of the drum and hat portion of the rotor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 02-05-26-002A > Feb > 03 > Brakes - Scraping Noises From Rear of Vehicle > Page 8982 8. Remove the rotor from the hub. If the rotor cannot be removed from the hub by pulling on the rotor, use J 46277 rotor removal tool. Notice: Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface, it may damage the rotor surface. 9. Using removal tool J 46277 on slide hammer J 6125B, remove the rotor by placing removal tool J 46277 in the vent section of the rotor at the twelve, three, six and nine o'clock positions, not necessarily in that order. 10. Clean the rust ridge from the drum portion of the rotor using a grinding stone and rotor resurfacing kit J 41013. 11. Remove the spring clip bolt (3) and retainer (2) and discard. Important: Minimum thickness of the parking brake shoe lining in any given spot is 1.5 mm (0.06 in). 12. Measure the parking brake shoe thickness in multiple spots. Replace the parking brake shoe if the thickness is less than 1.5 mm (0.06 in). Continue with Step 14. 13. If the parking brake shoe lining is greater than 1.5 mm (0.06 in), continue with Step 19. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 02-05-26-002A > Feb > 03 > Brakes - Scraping Noises From Rear of Vehicle > Page 8983 14. Rotate the parking brake shoe (1) out from the bottom and pull it out of the adjuster. Discard the shoe. 15. Remove the park brake shoe assembly from the vehicle by placing one of the open ends of the shoe over the axle flange and rotate the shoe until it has cleared the flange. 16. Turn the adjustment screw (1) to the fully home position in the notched adjustment nut. 17. Install the new park brake shoe assembly (1) from the parking brake shoe kit, P/N 88982875, to the vehicle by placing one of the open ends of the shoe over the axle flange and rotating the shoe until it is behind the flange. 18. Slide the shoe into the adjuster and position the shoe to the backing plate. Install the retaining spring clip (2) and bolt (3) from the parking brake shoe kit, P/N 88982875. If using parking brake service kit 88982875, SKIP Step 19. 19. Replace the retaining spring clip (2) and bolt (3) from the parking brake retaining spring clip kit, P/N 88982879. Tighten Tighten the bolt (3) to 5 N.m (44 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 02-05-26-002A > Feb > 03 > Brakes - Scraping Noises From Rear of Vehicle > Page 8984 20. Set the J 21177-A so that it contacts the inside diameter of the rotor. 21. Position the J 21177-A over the shoe and the lining at the widest point. Important: ^ The parking brake adjustment screw threads should not exceed 5 mm (0.2 in) of exposed thread. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 02-05-26-002A > Feb > 03 > Brakes - Scraping Noises From Rear of Vehicle > Page 8985 ^ The clearance between the park brake shoe and the rotor is 0.6604 mm (0.026 in). 22. The parking brake adjustment screw threads should not exceed 5 mm (0.2 inch) of exposed thread. Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange with the J 42450 hub cleaning kit. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. 23. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange. 24. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 25. Align the mark on the rotor with the mark on the hub and install the rotor by slowly turning the rotor while pushing the rotor towards the axle. 26. Install the caliper and the bracket as an assembly to the vehicle. 27. Perform the following procedure before installing the caliper bracket mounting bolts. ^ Remove all traces of the original adhesive. ^ Clean the threads of the bolt with brake parts cleaner, P/N 12346139 (Canadian P/N 10953463), and allow to dry. ^ Apply threadlocker, GM P/N 12345493 (Canadian P/N 10953488), or Red LOCTITE(TM) # 272, to the threads of the bolt. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 28. Install the caliper bracket mounting bolts. Tighten Tighten the brake caliper bracket mounting bolts to 175 N.m (129 lb ft). 29. Repeat this procedure on the other side of the vehicle. 30. Tighten the nut to the intermediate cable at the equalizer. Tighten Tighten the nut to 3.5 N.m (31 lb in). 31. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in the Tires and Wheels sub-section of the Service Information (SI Document ID # 656965). 32. Lower the vehicle. 33. Verify that the self adjuster lock-out pin has been removed. 34. Fully apply and release the park brake pedal three times. Parts Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 02-05-26-002A > Feb > 03 > Brakes - Scraping Noises From Rear of Vehicle > Page 8986 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Shoe: > 02-05-26-001C > Jan > 05 > Brakes - Park Brake Shoe Retaining Clip Kit Parking Brake Shoe: All Technical Service Bulletins Brakes - Park Brake Shoe Retaining Clip Kit Bulletin No.: 02-05-26-001C Date: January 19, 2005 INFORMATION Subject: Rear Parking Brake Shoe Retaining Spring Clip Service Kit for Drum-in-Hat (DIH) Equipped Vehicles Models: 2004-2005 Buick Rainier 2002-2005 Cadillac Escalade Models 2002-2005 Chevrolet Avalanche 1998-2005 Chevrolet Blazer 1999-2005 Chevrolet Silverado Models 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet SSR, TrailBlazer Models 2003-2005 Chevrolet Astro, Express 1998-2005 GMC Jimmy 1999-2005 GMC Sierra Models 2000-2005 GMC Yukon Models 2002-2005 GMC Envoy Models 2003-2005 GMC Safari, Savana 1998-2004 Oldsmobile Bravada This Bulletin ONLY applies to 1500 series vehicles with four wheel disc brakes. Supercede: This bulletin is being revised to include additional models and clarify parts usage information. Please discard Corporate Bulletin Number 02-05-26-001B (Section 05 - Brakes). A rear parking brake retaining spring clip kit has been released for service. This kit consists of two parking brake hold down spring clips (2) and bolts (3). Note: Use J 46277 Rotor Removal Tool with J 6125-B Slide Hammer to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface, it may damage the rotor surface. During rear brake rotor removal, it is possible to damage the parking brake shoe retaining spring clip. Order this new kit when replacement of the clips is required but the parking brake shoes do not require replacement. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Shoe: > 02-05-26-001C > Jan > 05 > Brakes - Park Brake Shoe Retaining Clip Kit > Page 8992 Important: The spring clip kits mentioned in this bulletin do not address any parking brake concerns. Refer to the Parking Brakes sub-section of the Service Manual for any diagnostic information. Parts Information Parts are currently available from GMSPO. Warranty Information When removal of the rear brake rotors results in damage to the spring clips on vehicles under warranty, use the labor operation shown in conjunction with one of the kit part numbers listed above. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Shoe: > 02-05-26-001C > Jan > 05 > Brakes - Park Brake Shoe Retaining Clip Kit > Page 8993 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Page 8994 Parking Brake Shoe: Service and Repair Park Brake Shoe Replacement (without RPO NYS) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and the wheel. 3. Relieve the tension on the park brake cables by loosening the nut at the equalizer. 4. Remove the park brake cable from the park brake actuator lever. 5. Remove the rotor. 6. Turn the adjustment screw (1) to the fully home position in the notched adjustment nut. 7. Remove the park brake shoe assembly from the backing plate by removing the tips from the slots and sliding the shoe (2) towards the retaining spring (3) until the shoe disengages from the spring. 8. Remove the park brake shoe assembly from the vehicle by placing one of the open ends of the shoe over the axle flange and rotating the shoe until it has cleared the flange. Installation Procedure 1. Clean the debris and the dust from the park brake components using a clean shop cloth. 2. Align the slots in both the adjusting screw (1) and tappet to be parallel with the backing plate face. 3. Install the park brake shoe assembly to the vehicle by placing one of the open ends of the shoe (2) over the axle flange and rotating the shoe until it is behind the flange. 4. Position the park brake shoe (2) on the inboard side of the actuator. 5. Slide the park brake shoe (2) into position and seat into the retaining spring (3). 6. Inspect the shoe assembly position. The shoe must be central on the backing plate with both tips located in the slots. 7. Adjust the park brake shoe. 8. Install the rotor. 9. Install the park brake cable to the park brake actuator lever. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Page 8995 10. Tighten the nut to the intermediate cable at the equalizer. Tighten the nut to 3.5 Nm (31 inch lbs.). 11. install the tire and wheel. 12. Remove the safety stands. 13. Lower the vehicle. 14. Adjust park brake cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Park Brake Warning Lamp Switch Bolt .................................................................................................................................................. 3 Nm (25 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Specifications > Page 8999 Parking Brake Warning Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Specifications > Page 9000 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the body wiring harness junction block but do not disconnect the harness. 2. Remove the park brake warning lamp switch mounting bolt. 3. Remove the park brake warning lamp switch. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake lamp switch mounting bolt. Tighten the bolt to 3 Nm (25 inch lbs.). 3. Install the body wiring harness junction block. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Specifications Hydraulic Brake Booster: Specifications Power Brake Booster Nuts-Hydraulic ...................................................................................................................................................... 36 Nm (27 ft. lbs.) Hydraulic Power Assist ............................................................................................... .............................................................................. 90 mm (3.54 inch) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Specifications > Page 9005 Hydraulic Brake Booster: Service and Repair Hydraulic Brake Booster Replacement Notice: Hydraulic brake systems use two distinct and incompatible fluids. Power steering fluid is used in the hydraulic brake booster system. Brake fluid is used in the master cylinder and brake pipes. Use extreme care when selecting brake system fluids, or seal damage can result. Removal Procedure 1. Apply the park brake and block the wheels. 2. Disconnect the inlet hose, the steering gear, and the hoses from the booster assembly. 3. Remove the master cylinder. 4. Remove the stop lamp switch. 5. Remove the 4 booster to bulkhead nuts. 6. Remove the booster assembly. 7. Remove the gasket. Installation Procedure 1. Install the gasket. 2. Install the booster assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 4 booster to bulkhead nuts. Tighten the nuts to 36 Nm (26 ft. lbs.). 4. Install the stop lamp switch. 5. Install the master cylinder. 6. Connect the return hose, the steering gear, and the inlet hoses. 7. Bleed the hydraulic booster system. 8. Release the park brake and unblock the wheels. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Specifications Hydraulic Fluid Accumulator: Specifications Pressure Accumulator Switch (JL4) ........................................................................................................................................................ 3 Nm (30 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Specifications > Page 9009 Hydraulic Fluid Accumulator: Service and Repair Hydraulic Brake Booster Accumulator Replacement Tools Required ^ J26889 Accumulator Piston Compressor Removal Procedure Caution: The accumulator contains compressed gas. Always use the proper tools and follow the recommended procedures or persona Injury may result. Do not apply heat to accumulator. Do not attempt to repair an Inoperative accumulator. Always replace an inoperative accumulator with a new one. Dispose of an inoperative accumulator by drilling a 1.5 mm (1/16 inch) diameter hole through the end of the accumulator can, opposite the O-ring. Caution: Push rod removal is not recommended. Improper staking of the push rod to the Hydroboost reaction piston can result in a loss of brakes. If the rod or seals require service, the entire unit must be replaced. 1. Apply the park brake and block the wheels. 2. Depress brake pedal at least 10 times in order to relieve pressure in the accumulator. 3. Remove the master cylinder from the hydraulic booster. 4. Place the J26889 over the end of the accumulator. 5. Install the nut on the stud. 6. Depress the accumulator with a C-clamp. If the accumulator does not move with moderate pressure, remove the C-clamp and depress the brake pedal ten times in order to relieve pressure in the accumulator. 7. Rotate the retaining ring (2) until either end of the ring is under the access hole (1). 8. Depress and hold the retaining ring (2) with a small tool inserted into the access hole (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Specifications > Page 9010 9. Remove the accumulator retainer ring (1) using a small hook shaped tool. 10. Release the C-clamp. 11. Remove the nut from the stud. 12. Remove the J26889. 13. Remove the accumulator (2) and the O-ring seal (3) Installation Procedure 1. Lubricate all of the seals and the metal friction points with power steering fluid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Specifications > Page 9011 2. Install the accumulator (2) and the O-ring seal (3). 3. Place the J26889 over the end of the accumulator. 4. Install the nut on the stud. 5. Depress the accumulator with a C-clamp. 6. Install the accumulator retainer ring (1). 7. Release the C-clamp. 8. Remove the nut from the stud. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Specifications > Page 9012 9. Remove the J26889. 10. Install the master cylinder to the hydraulic booster. 11. Release the park brake and unblock the wheels. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Power Brake Booster Nuts-Vacuum ......................................................................................................................................................... 36 Nm (27 ft. lbs.) Vacuum Power Assist ................................................................................................. .............................................................................. 65 mm (2.56 inch) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 9016 Vacuum Brake Booster: Service and Repair Vacuum Brake Booster Replacement Removal Procedure 1. Apply the park brake and block the wheels. 2. Remove the brake master cylinder. 3. Remove the vacuum hose from the brake booster check valve. 4. Remove the pushrod retaining clip (4) from the brake pedal stud (1). 5. Remove the stop lamp switch (2) and the pushrod (3) from the brake pedal stud (1). 6. Remove the 4 vacuum booster mounting nuts. 7. Remove the vacuum booster. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 9017 8. Remove the gasket from the booster and discard. Installation Procedure 1. Install the gasket to the booster. 2. Install the vacuum booster. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 4 vacuum booster mounting nuts. Tighten the nuts to 36 Nm (27 ft. lbs.). 4. Install the pushrod (3) and the stop lamp switch (2) to the brake pedal stud (1). 5. Install the pushrod retaining clip (4) to the brake pedal stud (1). 6. Install the vacuum hose to the brake booster check valve. 7. Install the master cylinder. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 9018 8. Release the park brake and unblock the wheels. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Service and Repair Vacuum Brake Booster Check Valve: Service and Repair Vacuum Brake Booster Check Valve and/or Hose Replacement Removal Procedure 1. Remove the vacuum brake booster check valve from the vacuum brake booster. 2. Remove the vacuum brake booster hose clamp at the check valve. 3. Remove the vacuum brake booster check valve from the hose. 4. Remove the manifold sight shield-4.8L, 5.3L, 6.0L. 5. Disconnect the vacuum brake booster hose at the engine-4.8L, 5.3L, 6.0L. 6. Disconnect the vacuum brake booster hose at the engine 4.3L. 7. Remove the vacuum brake booster hose from the vehicle. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Service and Repair > Page 9022 1. Connect the vacuum brake booster hose at the engine 4.8L, 5.3L, 6.0L. 2. Connect the vacuum brake booster hose at the engine - 4.3L. 3. Install the manifold sight shield 4.8L, 5.3L, 6.0L. 4. Install the vacuum brake booster check valve to the hose. 5. Install the vacuum brake booster hose clamp to the check valve. 6. Install the vacuum brake booster check valve to the vacuum brake booster. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 9032 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 9038 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 9039 Electronic Brake Control Module: Specifications EBCM to BPMV Torx Bolts .................................................................................................................. ................................................. 5 Nm (39 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 9040 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 9043 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 9044 Electronic Brake Control Module: Diagrams C2 - W/O VSES Electronic Brake Control Module (EBCM) - C2 - w/o VSES Part 1 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 9045 Part 2 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 9046 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 9047 Electronic Brake Control Module: Diagrams C2 - W/O VSES Electronic Brake Control Module (EBCM) - C2 - w/o VSES Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 9048 Part 1 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 9049 Part 2 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 9050 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 9051 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module (EBCM) Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Electronic Brake Control Module (EBCM) Replacement (w/o JL4) Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. 3. Thoroughly wash all contaminants from around the EHCU (1). 4. Disconnect the electrical connectors from the EBCM. 5. Loosen or remove 3 bolts (4) securing the EHCU mounting bracket (3) to the frame rail (5). 6. Gently move the EHCU down enough to remove the four mounting screws that fasten the EBCM(2) to the BPMV(1). 7. Remove the EBCM (2) from the BPMV (1). Removal may require a light amount of force. 8. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module (EBCM) > Page 9054 1. Install the EBCM (2) on to the BPMV(1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four new screws in the EBCM (2). Tighten the four screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Install or tighten three EHCU bracket mounting bolts. Tighten the EHCU bracket mounting bolts to 25 Nm (18 ft. lbs.). 4. Connect the electrical connectors to the EBCM. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 8. Return to Diagnostic Starting Point - Antilock Brake System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module (EBCM) > Page 9055 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) (W/JL4) Electronic Brake Control Module (EBCM) Replacement (w/ JL4) Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. 3. Thoroughly wash all contaminants from around the EHCU (1). 4. Disconnect the brake fluid pressure sensor (7) and pressure accumulator switch (4) electrical connectors. 5. Remove the four mounting screws that fasten the EBCM (2) to the BPMV (1). 6. Remove the EBCM (2) from the BPMV (1). Removal may require a light amount of force. Important: Note the routing of the jumper harnesses for reinstallation. 7. Remove the EBCM and jumper harnesses from the vehicle. 8. Remove the jumper harnesses from the EBCM 9. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure 1. Install the jumper harnesses to the EBCM. 2. Install the EBCM and jumper harnesses to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module (EBCM) > Page 9056 Important: ^ Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. ^ Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 3. Install the EBCM (2) on to the BPMV (1). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the four new screws in the EBCM (2). Tighten the four screws to 5 Nm (39 inch lbs.) in an X-pattern. 5. Connect the brake fluid pressure sensor (7) and pressure accumulator switch (4) electrical connectors. 6. Lower the vehicle. 7. Connect the negative battery cable. 8. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 9. Return to Diagnostic Starting Point - Antilock Brake System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Diagrams Inverting Driver Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 9064 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector from the fluid level sensor. 2. Remove the fluid level sensor (1). Use a needle nose pliers in order to compress the locking tabs at the opposite side of the master cylinder. Installation Procedure 1. Install the fluid level sensor (1) until the locking tabs snap into place. 2. Connect the electrical connector to the fluid level sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Specifications Brake Fluid Pressure Sensor/Switch: Specifications Brake Fluid Pressure Sensor (JL4) ........................................................................................................................................................... 16 Nm (12 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > MPA Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > MPA Switch > Page 9070 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Service and Repair > Brake Fluid Pressure Sensor Replacement Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Fluid Pressure Sensor Replacement Brake Fluid Pressure Sensor Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the alien bolt (2) from the Brake Pressure Modulator Valve (BPMV) mounting bracket (3) located on the sensor side. 3. Raise the BPMV to access the brake fluid pressure sensor. 4. Disconnect the electrical connector from the brake fluid pressure sensor. Important: The replacement of the old brake fluid pressure sensor must be performed quickly to reduce the amount of fluid that is lost during the procedure. 5. Use a wrench to keep the brake fluid pressure sensor collar from turning (1). Remove the brake fluid pressure sensor (2) from the BPMV. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Service and Repair > Brake Fluid Pressure Sensor Replacement > Page 9073 Notice: Refer to Fastener Notice in Service Precautions. 1. Quickly install the new brake fluid pressure sensor (2) to the BPMV as soon as the old sensor has been removed. Use a wrench to keep the brake fluid pressure sensor collar from turning (1). Tighten the brake fluid pressure sensor to 16 Nm (12 ft. lbs.). 2. Install the alien bolt (2) to the Brake Pressure Modulator Valve (BPMV) mounting bracket (3). Tighten the alien bolt to 9 Nm (7 ft. lbs.). 3. Connect the electrical connector to the brake fluid pressure sensor. 4. Lower the vehicle. 5. Check and fill the brake fluid level in the master cylinder. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Service and Repair > Brake Fluid Pressure Sensor Replacement > Page 9074 Brake Fluid Pressure Sensor/Switch: Service and Repair Pressure Accumulator Switch Replacement Pressure Accumulator Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the bolts (2) that secure the Brake Pressure Modulator Valve (BPMV) (1) to the mounting bracket (3). 3. Disconnect the electrical connector from the pressure accumulator switch. 4. Position the BPMV to be able to remove the pressure accumulator switch. 5. Remove the pressure accumulator switch from the BPMV. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Service and Repair > Brake Fluid Pressure Sensor Replacement > Page 9075 Notice: Refer to Fastener Notice in Service Precautions. 1. Install the pressure accumulator switch to the BPMV. Tighten the pressure accumulator switch to 3 Nm (30 inch lbs.). 2. Connect the electrical connector to the pressure accumulator switch. 3. Install the Brake Pressure Modulator Valve (BPMV) (1) and the bolts (2) to the mounting bracket (3). Tighten the bolts to 9 Nm (7 ft. lbs.). 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Park Brake Warning Lamp Switch Bolt .................................................................................................................................................. 3 Nm (25 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Specifications > Page 9079 Parking Brake Warning Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Specifications > Page 9080 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the body wiring harness junction block but do not disconnect the harness. 2. Remove the park brake warning lamp switch mounting bolt. 3. Remove the park brake warning lamp switch. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake lamp switch mounting bolt. Tighten the bolt to 3 Nm (25 inch lbs.). 3. Install the body wiring harness junction block. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 9084 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Stabilitrak Traction Control Switch: Service and Repair Stabilitrak Traction Control Switch Replacement (Stabilitrak) Removal Procedure 1. Remove Instrument Panel (IP) bezel. 2. Gently lift the retaining tabs (2) and remove the stabilitrak switch (3) from the instrument panel (IP) assembly (1). 3. Disconnect the harness connector from the stabilitrak switch. Installation Procedure 1. Connect the harness connector to the stabilitrak switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Stabilitrak > Page 9087 2. Install the stabilitrak switch (3) into the Instrument Panel (IP) assembly (1) 3. Ensure that the switch is secure into both retaining tabs (2). 4. Install instrument panel (IP) bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Stabilitrak > Page 9088 Traction Control Switch: Service and Repair Traction Control Traction Control Switch Replacement (Traction Control) Removal Procedure 1. Remove instrument panel (IP) bezel. 2. Gently lift the switch retaining tabs (1) and remove the traction control switch (2) from the Instrument Panel (IP) assembly (3). 3. Disconnect the harness connector from the traction control switch. Installation Procedure 1. Connect the harness connector to the traction control switch. 2. Install the traction control switch (2) into the instrument panel (IP) assembly (3), making sure that all of the switch retaining tabs (1) are engaged. 3. Install Instrument Panel (IP) bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall Possible Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 05068C Date: 080306 Recall - Possible Front Wheel Speed Sensor Corrosion SAFETY Bulletin No.: 05068C Date: March 06, 2008 Subject: 05068C - FRONT WHEEL SPEED SENSOR CORROSION Models: 1999-2002 CHEVROLET SILVERADO 2000-2002 CHEVROLET TAHOE, SUBURBAN 2002 CHEVROLET AVALANCHE 1999-2002 GMC SIERRA 2000-2002 GMC YUKON, YUKON XL LOCATED IN THE SEVERE CORROSION AREAS LISTED BELOW Supercede: Some breakpoints in this bulletin have been revised. Additional vehicles that have moved into the severe corrosion areas have been added. Please discard all copies of bulletin 05068B, issued April 2006. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in the areas shown above. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is traveling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph) the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited a crash could occur. Correction Dealers are to inspect clean and treat the affected area. In some cases the front wheel speed sensor may require replacement. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall Possible Front Wheel Speed Sensor Corrosion > Page 9097 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall Possible Front Wheel Speed Sensor Corrosion > Page 9098 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra and 2000-2002 GMC Yukon, Yukon XL vehicles located in severe corrosion areas and built within the VIN breakpoints shown. Important: Dealers retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required order appropriate part from GMSPO. Customer Reimbursement All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center not by dealers. Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement. Claim Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall Possible Front Wheel Speed Sensor Corrosion > Page 9099 Submit a Product Recall Claim with the information shown. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. All unsold new vehicles in dealers possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers regardless of mileage age of vehicle or ownership from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory and for which there is no customer information indicated on the dealer listing are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose since the customer may not as yet have received the notification letter. In summary whenever a vehicle subject to this recall enters your vehicle inventory or is in your dealership for service in the future you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall Possible Front Wheel Speed Sensor Corrosion > Page 9100 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. 1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire or equivalent whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall Possible Front Wheel Speed Sensor Corrosion > Page 9101 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). ^ If the sensor mounting surface is NOT flat (1) the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2) the sensor IS to be reused. Proceed to Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall Possible Front Wheel Speed Sensor Corrosion > Page 9102 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed harness electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame upper control arm and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush sandpaper emery cloth scotch-brite or equivalent thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust or corrosion. 18. Using compressed air remove all debris from the bearing hub surface. 19. Using a clean shop towel clean the sensor and the 0-ring. Important: While the corrosion inhibitor is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes) apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall Possible Front Wheel Speed Sensor Corrosion > Page 9103 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 N.m (13 lb ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated after the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply threadlocker to the threads of the bolts. 28. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles - 175 N.m (129 lb ft) ^ 2500 Series vehicles - 300 N.m (221 lb ft) 29. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 N.m (140 lb ft). 30. Complete Steps 21-30 on the opposite side front wheel speed sensor. 31. Lower the vehicle. 32. With the engine OFF gradually apply the brake pedal to approximately 2/3 of its travel distance. 33. Slowly release the brake pedal. 34. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 05068C > Mar > 08 > Recall Possible Front Wheel Speed Sensor Corrosion > Page 9104 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > NHTSA05V379000 > Aug > 05 > Recall 05V379000: Wheel Speed Sensor Cleaning Wheel Speed Sensor: Recalls Recall 05V379000: Wheel Speed Sensor Cleaning MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Avalanche 1999-2002 Chevrolet/Silverado 1999-2002 Chevrolet/Suburban 1999-2002 Chevrolet/Tahoe 1999-2002 GMC/Sierra 1999-2002 GMC/Yukon 1999-2002 GMC/Yukon XL 1999-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBE : 05V379000 MFG'S REPORT DATE: August 29, 2005 COMPONENT: Service Brakes, Hydraulic: Antilock POTENTIAL NUMBER OF UNITS AFFECTED: 804000 SUMMARY: Certain pickup trucks and sport utility vehicles may experience unwanted Antilock Brake System (ABS) activation. This condition is more likely to occur in environmentally corrosive areas. This recall will be launched in the "SALT BELT" states of Connecticut, Illinois, Indiana, Massachusetts, Maine, Michigan, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont and West Virginia only. CONSEQUENCE: This can cause increased stopping distances during low-speed brake applications, which could result in a crash. REMEDY: Dealers are to remove the wheel speed sensor and thoroughly clean the wheel speed sensor mounting surface on the bearing, apply rust inhibitor to the cleaned surface, grease the mounting surface, reinstall the wheel speed sensor, and check the peak-to-peak output voltage to ensure the wheel speed signal is within specifications. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05068. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 04094 Date: 050125 Recall - Front Wheel Speed Sensor Corrosion Product Safety - Front Wheel Speed Sensor Corrosion # 04094 - (Jan 25, 2005) Models: 1999-2002 Chevrolet Silverado 2000-2002 Chevrolet Tahoe, Suburban 2002 Chevrolet Avalanche 1999-2002 GMC Sierra 2000-2002 GMC Yukon, Yukon XL Located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, Prince Edward Island Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is travelling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph), the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited, a crash could occur. Correction Dealers are to clean and treat the affected area, and in some cases, replace the front wheel speed sensor. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9113 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9114 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required, order appropriate part from GMSPO. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9115 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by January 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. ^ Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9116 Claim Information Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9117 not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. A. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. B. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. C. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9118 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped, remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinist's scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9119 ^ If the sensor mounting surface is NOT flat (1), the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2), the sensor IS to be reused. Proceed to Step 16. 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed sensor electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame, upper control arm, and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush, sandpaper, emery cloth, scotch brite, or equivalent, thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust of corrosion. 18. Using compressed air, remove all debris from the bearing hub surface. 19. Using a clean shop towel, clean the sensor and the 0-ring. Important: While the corrosion is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin, to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 Nm (13 lb-ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmVs. If the reading is less than Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9120 350 ACmVs, the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated afier the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 28. Remove all traces of the original adhesive patch. A. Clean the threads of the bolt with brake parts cleaner, or the equivalent, and allow to dry. B. Apply threadlocker to the threads of the bolts. 29. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles -- 175 Nm (129 lb-ft) ^ 2500 Series vehicles -- 300 Nm (221 lb-ft) 30. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 Nm (140 lb-ft). 31. Complete Steps 21-30 on the opposite side front wheel speed sensor. 32. Lower the vehicle. 33. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 34. Slowly release the brake pedal. 35. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Recalls: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9121 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: Customer Interest Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 9127 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 9133 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 05068C Date: 080306 Recall - Possible Front Wheel Speed Sensor Corrosion SAFETY Bulletin No.: 05068C Date: March 06, 2008 Subject: 05068C - FRONT WHEEL SPEED SENSOR CORROSION Models: 1999-2002 CHEVROLET SILVERADO 2000-2002 CHEVROLET TAHOE, SUBURBAN 2002 CHEVROLET AVALANCHE 1999-2002 GMC SIERRA 2000-2002 GMC YUKON, YUKON XL LOCATED IN THE SEVERE CORROSION AREAS LISTED BELOW Supercede: Some breakpoints in this bulletin have been revised. Additional vehicles that have moved into the severe corrosion areas have been added. Please discard all copies of bulletin 05068B, issued April 2006. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in the areas shown above. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is traveling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph) the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited a crash could occur. Correction Dealers are to inspect clean and treat the affected area. In some cases the front wheel speed sensor may require replacement. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 9138 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 9139 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra and 2000-2002 GMC Yukon, Yukon XL vehicles located in severe corrosion areas and built within the VIN breakpoints shown. Important: Dealers retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required order appropriate part from GMSPO. Customer Reimbursement All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center not by dealers. Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement. Claim Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 9140 Submit a Product Recall Claim with the information shown. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. All unsold new vehicles in dealers possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers regardless of mileage age of vehicle or ownership from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory and for which there is no customer information indicated on the dealer listing are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose since the customer may not as yet have received the notification letter. In summary whenever a vehicle subject to this recall enters your vehicle inventory or is in your dealership for service in the future you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 9141 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. 1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire or equivalent whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 9142 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). ^ If the sensor mounting surface is NOT flat (1) the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2) the sensor IS to be reused. Proceed to Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 9143 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed harness electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame upper control arm and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush sandpaper emery cloth scotch-brite or equivalent thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust or corrosion. 18. Using compressed air remove all debris from the bearing hub surface. 19. Using a clean shop towel clean the sensor and the 0-ring. Important: While the corrosion inhibitor is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes) apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 9144 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 N.m (13 lb ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated after the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply threadlocker to the threads of the bolts. 28. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles - 175 N.m (129 lb ft) ^ 2500 Series vehicles - 300 N.m (221 lb ft) 29. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 N.m (140 lb ft). 30. Complete Steps 21-30 on the opposite side front wheel speed sensor. 31. Lower the vehicle. 32. With the engine OFF gradually apply the brake pedal to approximately 2/3 of its travel distance. 33. Slowly release the brake pedal. 34. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 9145 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > NHTSA05V379000 > Aug > 05 > Recall 05V379000: Wheel Speed Sensor Cleaning Wheel Speed Sensor: All Technical Service Bulletins Recall 05V379000: Wheel Speed Sensor Cleaning MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Avalanche 1999-2002 Chevrolet/Silverado 1999-2002 Chevrolet/Suburban 1999-2002 Chevrolet/Tahoe 1999-2002 GMC/Sierra 1999-2002 GMC/Yukon 1999-2002 GMC/Yukon XL 1999-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBE : 05V379000 MFG'S REPORT DATE: August 29, 2005 COMPONENT: Service Brakes, Hydraulic: Antilock POTENTIAL NUMBER OF UNITS AFFECTED: 804000 SUMMARY: Certain pickup trucks and sport utility vehicles may experience unwanted Antilock Brake System (ABS) activation. This condition is more likely to occur in environmentally corrosive areas. This recall will be launched in the "SALT BELT" states of Connecticut, Illinois, Indiana, Massachusetts, Maine, Michigan, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont and West Virginia only. CONSEQUENCE: This can cause increased stopping distances during low-speed brake applications, which could result in a crash. REMEDY: Dealers are to remove the wheel speed sensor and thoroughly clean the wheel speed sensor mounting surface on the bearing, apply rust inhibitor to the cleaned surface, grease the mounting surface, reinstall the wheel speed sensor, and check the peak-to-peak output voltage to ensure the wheel speed signal is within specifications. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05068. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 04094 Date: 050125 Recall - Front Wheel Speed Sensor Corrosion Product Safety - Front Wheel Speed Sensor Corrosion # 04094 - (Jan 25, 2005) Models: 1999-2002 Chevrolet Silverado 2000-2002 Chevrolet Tahoe, Suburban 2002 Chevrolet Avalanche 1999-2002 GMC Sierra 2000-2002 GMC Yukon, Yukon XL Located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, Prince Edward Island Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is travelling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph), the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited, a crash could occur. Correction Dealers are to clean and treat the affected area, and in some cases, replace the front wheel speed sensor. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9154 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9155 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required, order appropriate part from GMSPO. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9156 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by January 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. ^ Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9157 Claim Information Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9158 not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. A. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. B. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. C. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9159 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped, remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinist's scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9160 ^ If the sensor mounting surface is NOT flat (1), the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2), the sensor IS to be reused. Proceed to Step 16. 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed sensor electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame, upper control arm, and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush, sandpaper, emery cloth, scotch brite, or equivalent, thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust of corrosion. 18. Using compressed air, remove all debris from the bearing hub surface. 19. Using a clean shop towel, clean the sensor and the 0-ring. Important: While the corrosion is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin, to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 Nm (13 lb-ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmVs. If the reading is less than Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9161 350 ACmVs, the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated afier the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 28. Remove all traces of the original adhesive patch. A. Clean the threads of the bolt with brake parts cleaner, or the equivalent, and allow to dry. B. Apply threadlocker to the threads of the bolts. 29. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles -- 175 Nm (129 lb-ft) ^ 2500 Series vehicles -- 300 Nm (221 lb-ft) 30. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 Nm (140 lb-ft). 31. Complete Steps 21-30 on the opposite side front wheel speed sensor. 32. Lower the vehicle. 33. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 34. Slowly release the brake pedal. 35. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9162 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 9168 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 05068C Date: 080306 Recall - Possible Front Wheel Speed Sensor Corrosion SAFETY Bulletin No.: 05068C Date: March 06, 2008 Subject: 05068C - FRONT WHEEL SPEED SENSOR CORROSION Models: 1999-2002 CHEVROLET SILVERADO 2000-2002 CHEVROLET TAHOE, SUBURBAN 2002 CHEVROLET AVALANCHE 1999-2002 GMC SIERRA 2000-2002 GMC YUKON, YUKON XL LOCATED IN THE SEVERE CORROSION AREAS LISTED BELOW Supercede: Some breakpoints in this bulletin have been revised. Additional vehicles that have moved into the severe corrosion areas have been added. Please discard all copies of bulletin 05068B, issued April 2006. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in the areas shown above. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is traveling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph) the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited a crash could occur. Correction Dealers are to inspect clean and treat the affected area. In some cases the front wheel speed sensor may require replacement. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 9174 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 9175 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra and 2000-2002 GMC Yukon, Yukon XL vehicles located in severe corrosion areas and built within the VIN breakpoints shown. Important: Dealers retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required order appropriate part from GMSPO. Customer Reimbursement All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center not by dealers. Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement. Claim Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 9176 Submit a Product Recall Claim with the information shown. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. All unsold new vehicles in dealers possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers regardless of mileage age of vehicle or ownership from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory and for which there is no customer information indicated on the dealer listing are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose since the customer may not as yet have received the notification letter. In summary whenever a vehicle subject to this recall enters your vehicle inventory or is in your dealership for service in the future you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 9177 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. 1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire or equivalent whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 9178 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). ^ If the sensor mounting surface is NOT flat (1) the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2) the sensor IS to be reused. Proceed to Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 9179 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed harness electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame upper control arm and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush sandpaper emery cloth scotch-brite or equivalent thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust or corrosion. 18. Using compressed air remove all debris from the bearing hub surface. 19. Using a clean shop towel clean the sensor and the 0-ring. Important: While the corrosion inhibitor is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes) apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 9180 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 N.m (13 lb ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated after the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply threadlocker to the threads of the bolts. 28. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles - 175 N.m (129 lb ft) ^ 2500 Series vehicles - 300 N.m (221 lb ft) 29. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 N.m (140 lb ft). 30. Complete Steps 21-30 on the opposite side front wheel speed sensor. 31. Lower the vehicle. 32. With the engine OFF gradually apply the brake pedal to approximately 2/3 of its travel distance. 33. Slowly release the brake pedal. 34. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05068C > Mar > 08 > Recall - Possible Front Wheel Speed Sensor Corrosion > Page 9181 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > NHTSA05V379000 > Aug > 05 > Recall 05V379000: Wheel Speed Sensor Cleaning Wheel Speed Sensor: All Technical Service Bulletins Recall 05V379000: Wheel Speed Sensor Cleaning MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Avalanche 1999-2002 Chevrolet/Silverado 1999-2002 Chevrolet/Suburban 1999-2002 Chevrolet/Tahoe 1999-2002 GMC/Sierra 1999-2002 GMC/Yukon 1999-2002 GMC/Yukon XL 1999-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBE : 05V379000 MFG'S REPORT DATE: August 29, 2005 COMPONENT: Service Brakes, Hydraulic: Antilock POTENTIAL NUMBER OF UNITS AFFECTED: 804000 SUMMARY: Certain pickup trucks and sport utility vehicles may experience unwanted Antilock Brake System (ABS) activation. This condition is more likely to occur in environmentally corrosive areas. This recall will be launched in the "SALT BELT" states of Connecticut, Illinois, Indiana, Massachusetts, Maine, Michigan, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont and West Virginia only. CONSEQUENCE: This can cause increased stopping distances during low-speed brake applications, which could result in a crash. REMEDY: Dealers are to remove the wheel speed sensor and thoroughly clean the wheel speed sensor mounting surface on the bearing, apply rust inhibitor to the cleaned surface, grease the mounting surface, reinstall the wheel speed sensor, and check the peak-to-peak output voltage to ensure the wheel speed signal is within specifications. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05068. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion Technical Service Bulletin # 04094 Date: 050125 Recall - Front Wheel Speed Sensor Corrosion Product Safety - Front Wheel Speed Sensor Corrosion # 04094 - (Jan 25, 2005) Models: 1999-2002 Chevrolet Silverado 2000-2002 Chevrolet Tahoe, Suburban 2002 Chevrolet Avalanche 1999-2002 GMC Sierra 2000-2002 GMC Yukon, Yukon XL Located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, Prince Edward Island Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island. These vehicles may have a condition permitting corrosion to occur between the front hub/bearing assembly and the wheel speed sensor. If the brakes are applied while the vehicle is travelling at a speed of greater than 6 km/h (3.7 mph) but less than 16 km/h (10 mph), the corrosion may cause an unwanted anti-lock brake system (ABS) activation. If this condition occurred where stopping distance is limited, a crash could occur. Correction Dealers are to clean and treat the affected area, and in some cases, replace the front wheel speed sensor. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9190 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9191 Involved are certain 1999-2002 Chevrolet Silverado, 2000-2002 Chevrolet Tahoe, Suburban, 2002 Chevrolet Avalanche, 1999-2002 GMC Sierra, 2000-2002 GMC Yukon, Yukon XL vehicles located in Ontario, Quebec, Newfoundland, New Brunswick, Nova Scotia, and Prince Edward Island and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Note: Very few vehicles will require front wheel speed sensor replacement; if required, order appropriate part from GMSPO. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9192 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by January 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. ^ Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9193 Claim Information Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9194 not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. A. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. B. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. C. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9195 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped, remove the rotor retaining push nuts from the wheel studs. 8. Remove the rotor. 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10. Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced. 11. Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinist's scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9196 ^ If the sensor mounting surface is NOT flat (1), the sensor must be replaced. Proceed to the next step and replace the sensor. ^ If the sensor mounting surface IS flat (2), the sensor IS to be reused. Proceed to Step 16. 12. Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13. Disconnect the wheel speed sensor electrical connector (1) from the vehicle wiring harness. 14. Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15. Attach the wheel speed sensor harness to the frame, upper control arm, and the knuckle. 16. Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17. Using a wire brush, sandpaper, emery cloth, scotch brite, or equivalent, thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust of corrosion. 18. Using compressed air, remove all debris from the bearing hub surface. 19. Using a clean shop towel, clean the sensor and the 0-ring. Important: While the corrosion is drying in the next step, begin performing Steps 3-20 on the opposite side front wheel speed sensor. 20. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) listed in this bulletin, to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. 21. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a light coating of the specified grease to the complete sensor mounting surface on the bearing hub and to the sensor and 0-ring. 22. Remove the temporary plug from the hole in the bearing hub. 23. Install the wheel speed sensor in the bearing hub and install the bolt. Ensure that the sensor is seated flat against the hub. Tighten Tighten the wheel speed sensor mounting bolt to 18 Nm (13 lb-ft). 24. Disconnect the front wheel speed sensor connector and place a digital volt meter (DVM) across the terminals of the wheel speed sensor connector. Rotate the bearing at approximately one revolution per second. The minimum reading should be at least 350 ACmVs. If the reading is less than Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9197 350 ACmVs, the wheel speed sensor must be replaced. Follow Steps 12-15 for instructions on replacing the wheel speed sensor. This step must be repeated afier the new sensor has been installed. Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake. Important: If the rotor was removed using the jack screw method, you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 25. Align the rotor to its original position on the hub and install the rotor. 26. Install the caliper and caliper mounting bracket assembly. 27. Perform the following procedure before installing the brake caliper bracket mounting bolts. 28. Remove all traces of the original adhesive patch. A. Clean the threads of the bolt with brake parts cleaner, or the equivalent, and allow to dry. B. Apply threadlocker to the threads of the bolts. 29. Install the caliper bracket mounting bolts. Tighten the brake caliper mounting bracket mounting bolts to the specification listed below. Tighten ^ 1500 Series vehicles -- 175 Nm (129 lb-ft) ^ 2500 Series vehicles -- 300 Nm (221 lb-ft) 30. Install the front tire and wheel assembly. Tighten Tighten the wheel nuts to 190 Nm (140 lb-ft). 31. Complete Steps 21-30 on the opposite side front wheel speed sensor. 32. Lower the vehicle. 33. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 34. Slowly release the brake pedal. 35. Wait 15 seconds and repeat Steps 32-33 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04094 > Jan > 05 > Recall - Front Wheel Speed Sensor Corrosion > Page 9198 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 9199 Wheel Speed Sensor: Specifications Front Wheel Speed Sensor Mounting Bolt ............................................................................................................................................... 18 Nm (13 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 9200 Wheel Speed Sensor - RF (4WD) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > LF Wheel Speed Sensor (WSS) - LF Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > LF > Page 9203 Wheel Speed Sensor (WSS) - RF Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 9204 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor (2). 4. Remove the Wheel Speed Sensor (WSS) mounting bolt. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 5. Remove the wheel speed sensor (5) from the hub/bearing assembly (4). 6. Remove the WSS cable mounting clip from the knuckle. 7. Remove the WSS cable mounting clip from the upper control arm. 8. Remove the WSS cable mounting clip from the frame attachment point. 9. Remove the WSS cable electrical connector. Installation Procedure 1. Install the WSS (5) into the hub/bearing assembly (4). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the WSS mounting bolt. Tighten the WSS mounting bolt to 18 Nm (13 ft. lbs.). 3. Install the WSS cable mounting clip to the knuckle. 4. Install the WSS cable mounting clip to the upper control arm. 5. Install the WSS cable mounting clip to the frame attachment point. 6. Connect the WSS cable electrical connector. 7. Install the brake rotor (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 9205 8. Install the tire and wheel. 9. Return to Diagnostic Starting Point - Antilock Brake System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Specifications Yaw Rate Sensor: Specifications Yaw Rate Sensor/Lateral Accelerometer Nut ........................................................................................................................................ 10 Nm (89 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Specifications > Page 9209 Yaw Rate Sensor: Service and Repair Yaw Rate Sensor/Lateral Accelerometer Replacement Removal Procedure 1. Remove the front floor console bezel. 2. Disconnect the yaw rate sensor/lateral accelerometer electrical connector. 3. Remove the 3 yaw rate sensor/lateral accelerometer nuts. 4. Remove the yaw rate sensor/lateral accelerometer from the vehicle. Installation Procedure Important: Use care not to bend or distort the bracket that supports the yaw rate sensor/lateral accelerometer. 1. Install the yaw rate sensor/lateral accelerometer to the bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 yaw rate sensor/lateral accelerometer nuts to the bracket. Tighten the nuts to 10 Nm (89 inch lbs.). 3. Connect the yaw rate sensor/lateral accelerometer electrical connector. 4. Install the front floor bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 9221 Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 9222 Starter Relay: Service and Repair REMOVAL PROCEDURE 1. Remove the underhood bussed electrical center (UBEC) cover. 2. Remove the starter motor relay. INSTALLATION PROCEDURE 1. Install the starter motor relay. 2. Install the underhood bussed electrical center (UBEC) cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) Negative: Service and Repair Battery Cable Replacement (Negative) REMOVAL PROCEDURE CAUTION: refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. If equipped with a 4.8L, 5.3L, or 6.OL engine, remove the battery cable bracket bolt and bracket from the power steering pump. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) > Page 9229 3. If equipped, disconnect the accessory power fuse block front wiring harness electrical connector from the negative cable connector. 4. If equipped with a 4.8L, 5.3L, or 6.OL engine, remove the negative cable clip from positive cable clip. 5. Raise and suitably support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle. 6. Remove the engine wiring harness 7. If equipped with a 8.1L engine, remove the negative cable clip from the positive cable clip. 8. Raise and suitably support the vehicle with safety stands. Refer to Lifting and JackThg the Vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) > Page 9230 9. Remove the engine wiring harness ground/negative cable bolt. 10. Reposition the wiring harness ground and negative cables. 11. Remove the forward lamp wiring harness ground/negative cable bolt. 12. Remove the negative battery cable. INSTALLATION PROCEDURE 1. Install the negative battery cable. 2. Position the negative cable and forward lamp wiring harness ring terminals to the frame. Insert the anti-rotation tab on the forward lamp wiring harness into the hole in the frame. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the forward lamp wiring harness ground/negative cable bolt. Tighten Tighten the forward lamp wiring harness ground/negative cable bolt to 9 N.m (80 lb in). IMPORTANT: The engine wiring harness ground is to be installed under the negative cable ground. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) > Page 9231 4. If equipped with a 8.1L engine, position the wiring harness ground and negative cables. Position the anti-rotation tab on the negative cable in the correct location. 5. Install the engine wiring harness ground/negative cable bolt. Tighten Tighten the engine wiring harness ground/negative cable bolt to 25 N.m (18 lb ft). 6. Lower the vehicle. 7. Install the negative cable clip to the positive cable clip. 8. If equipped with a 4.8L, 5.3L, or 6.OL engine, position the negative cable and engine wiring harness ring terminals to the engine block. Position the anti-rotation tab on the negative cable in the correct location. 9. Install the engine wiring harness ground/negative cable bolt. Tighten Tighten the engine wiring harness ground/negative cable bolt to 25 N.m (18 lb ft). 10. Lower the vehicle. 11. Install the negative cable clip to the positive cable clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) > Page 9232 12. If equipped, connect the accessory power fuse block front wiring harness electrical connector to the negative cable connector. 13. Install the battery cable bracket and bolt to the power steering pump Tighten Tighten the battery cable bracket bolt to 25 N.m (18 lb ft). 14. Connect the negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) > Page 9233 Negative: Service and Repair Battery Negative Cable Disconnect/Connect Procedure Single Battery REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. 3. Remove the battery ground negative cable and bolt from the battery. INSTALLATION PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions IMPORTANT: Clean any existing corrosion from the battery terminal bolt flange and the battery cable end. Install the battery ground negative cable and bolt to the battery. Tighten Tighten the battery terminal bolt to 17 N.m (13 lb ft). Auxiliary Battery REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) > Page 9234 CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. 3. Remove the battery ground negative cable and bolt from the battery. INSTALLATION PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. IMPORTANT: Clean any existing corrosion from the battery terminal bolt flange and the battery cable end. Install the battery ground negative cable and bolt to the battery. Tighten Tighten the battery terminal bolt to 17 N.m (13 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) > Page 9235 Negative: Service and Repair Battery Negative Cable Replacement - Auxiliary REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the auxiliary negative battery cable. 2. Remove the auxiliary battery cable clips from the studs at the front of dasti. 3. Remove the engine sight shield. 4. If equipped with a 4.8L, 5.3L, or 6.OL engine, remove the engine wiring harness/auxiliary negative battery cable bolt. 5. Remove the auxiliary negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) > Page 9236 6. If equipped with a 8.1L engine, remove the engine wiring harness/auxiliary negative battery cable bolt. 7. Remove the auxiliary negative battery cable. INSTALLATION PROCEDURE IMPORTANT: Install the auxiliary negative battery cable terminal behind the engine wiring harness ground terminal. 1. If equipped with a 8.1L engine, install the auxiliary negative battery cable. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the engine wiring harness/auxiliary negative battery cable bolt. Tighten Tighten the engine wiring harness/auxiliary negative battery cable bolt to 16 N.m (12 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) > Page 9237 4. If equipped with a 4.8L, 5.3L, or 6.OL engine, remove the engine wiring harness/auxiliary negative battery cable bolt. 5. Remove the auxiliary negative battery cable. 6. If equipped with a 8.1L engine, remove the engine wiring harness/auxiliary negative battery cable bolt. 7. Remove the auxiliary negative battery cable. INSTALLATION PROCEDURE IMPORTANT: Install the auxiliary negative battery cable terminal behind the engine wiring harness ground terminal. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) > Page 9238 1. If equipped with a 8.1L engine, install the auxiliary negative battery cable. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the engine wiring harness/auxiliary negative battery cable bolt. Tighten Tighten the engine wiring harness/auxiliary negative battery cable bolt to 16 N.m (12 lb ft). IMPORTANT: Install the engine winng harness grounci terminal on top of and inboard of the auxiliary negative battery cable ground crimp. 3. If equipped with a 4.8L, 5.3L, or 6.OL engine, install the auxiliary negative battery cable. 4. Install the engine wiring harness/auxiliary negative battery cable bolt. Tighten Tighten the engine wiring harness/auxiliary negative battery cable bolt to 16 N.m (12 lb ft). 5. Install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Negative) > Page 9239 6. Install the auxiliary battery cable clips to the studs at the front of dash. 7. Connect the auxiliary negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions Positive: Service Precautions BATTERY DISCONNECT CAUTION CAUTION: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Positive) Positive: Service and Repair Battery Cable Replacement (Positive) REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Unsnap the positive battery cable cap. 3. Disconnect the positive battery cable. IMPORTANT: The bolt is integral to the battery cable and is not removable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Positive) > Page 9245 4. Loosen the positive cable bolt at the underhood bussed electrical center (UBEC). 5. If necessary, remove the engine sight shield. 6. Unsnap the junction block cover. 7. Remove the positive battery cable (1) from the junction block. 8. If equipped with a 4.8 L, 5.3 L, or 6.0 L engine, remove the negative cable clip from the positive cable clip. 9. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Positive) > Page 9246 10. If equipped with a 8.1 L engine, remove the negative cable clip from the positive cable clip. 11. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 12. Remove the positive battery cable channel bolt. 13. Slide the channel pin out of the oil pan tab. 14. Remove the positive battery cable from the channel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Positive) > Page 9247 15. If equipped with a 4.8 L, 5.3 L, or 6.0 L engine, remove the battery cable bracket bolt and bracket from the power steering pump. 16. If equipped with a 4.8 L, 5.3 L, or 6.0 L engine, remove the starter lead nut. 17. Remove the positive cable from the starter. 18. Remove the positive cable clip from the clip on the oil pan. 19. Remove the positive cable from the clip on the oil pan. 20. Remove the positive battery cable. 21. If equipped with a 8.1 L engine, remove the starter lead nut. 22. Remove the positive cable from the starter. 23. Remove the positive cable clip nut. 24. Remove the positive cable from the engine harness clip. 25. Remove the positive battery cable. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Positive) > Page 9248 1. If equipped with a 8.1 L engine, install the positive battery cable. 2. Install the positive cable to the engine harness clip. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the positive cable clip nut. Tighten Tighten the positive cable clip nut to 8 N.m (71 lb in). 4. Install the positive cable to the starter. 5. Install the starter lead nut. Tighten Tighten the starter lead nut to 9 N.m (80 lb in). 6. If equipped with a 4.8 L, 5.3 L, or 6.0 L engine, Install the positive battery cable. 7. Install the positive cable to the clip on the oil pan. 8. Install the positive cable clip to the clip on the oil pan. 9. Install the positive cable to the starter. 10. Install the starter lead nut. Tighten Tighten the starter lead nut to 9 N.m (80 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Positive) > Page 9249 11. IF equipped with a 4.8 L, 5.3 L, or 6.0 L engine, install the battery cable bracket and bolt. Tighten Tighten the battery cable bracket bolt to 25 N.m (18 lb ft). 12. Install the positive battery cable to the channel. 13. Slide the channel pin into the oil pan tab. 14. Install the positive battery cable channel bolt. Tighten Tighten the battery cable channel bolt to 12 N.m (106 lb in). 15. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Positive) > Page 9250 16. If equipped with a 8.1 L engine, install the negative cable clip to the positive cable clip. 17. If equipped with a 4.8 L, 5.3 L, or 6.0 L engine, install the negative cable clip to the positive cable clip. 18. Install the positive cable (1) into the junction block. 19. Snap the junction block cover closed. 20. If necessary, install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Positive) > Page 9251 21. Tighten the positive cable bolt at the UBEC. Tighten Tighten the positive cable bolt at the UBEC to 9 N.m (80 lb in). 22. Connect the positive battery cable. Tighten Tighten the positive battery cable bolt to 17 N.m (13 lb ft). 23. Snap the positive battery cable cap closed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Positive) > Page 9252 24. Connect the negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Positive) > Page 9253 Positive: Service and Repair Battery Positive Cable Replacement - Auxiliary1 Auxiliary Battery to Battery Relay REMOVAL PROCEDURE 1. Remove the auxiliary battery. 2. Reposition the boot to expose the stud. 3. Remove the auxiliary positive cable to relay nut. 4. Unclip the mega fuse from the auxiliary battery tray. 5. Remove the auxiliary battery positive cable. INSTALLATION PROCEDURE 1. Install the auxiliary battery positive cable. 2. Clip the mega fuse to the auxiliary battery tray. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the auxiliary positive cable nut. Tighten Tighten the auxiliary positive cable to relay nut to 9 N.m (80 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Positive) > Page 9254 4. Position the boot to cover the stud. 5. Install the auxiliary battery. Battery Relay to Starter REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the auxiliary negative battery cable. 2. Reposition the boot to expose the stud. 3. Remove the auxiliary battery positive cable nut. 5. Remove the auxiliary battery positive cable to the auxiliary battery relay. 5. Remove the auxiliary battery positive cable clip from the auxiliary battery tray. 6. Raise and suitably support the vehicle. refer to Lifting and Jackmg the Vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Positive) > Page 9255 7. Remove the auxiliary battery positive cable clip bolt from the frame. 8. Remove the positive cable nut. 9. Remove the positive cable from the starter. 10. Remove the auxiliary positive battery cable from the starter. 11. Remove the auxiliary positive battery cable. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Positive) > Page 9256 1. Install the auxiliary positive battery cable. 2. Install the auxiliary positive battery cable to the starter. 3. Install the positive cable to the starter. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the positive cable nut. Tighten Tighten the nut to 9 N.m (80 lb in). 5. Install the auxiliary battery cable clip bolt to the frame. Tighten Tighten the bolt to 10 N.m (89 lb in). 6. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Cable Replacement (Positive) > Page 9257 7. Install the auxiliary positive battery cable clip to the auxiliary battery tray. 8. Install the auxiliary battery positive cable to the auxiliary battery relay. 9. Install the auxiliary battery positive cable nut. Tighten Tighten the auxiliary battery positive cable nut to 8 N.m (71 lb in). 10. Position the boot to cover the stud. 11. Connect the auxiliary negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Amperage Alternator: Specifications Amperage Application ........................................................................................................................................... ........................................................... Specification Base Generator Model .................................................................................................................................. ........................................................... Delphi AD230 Rated Output .................................................... ............................................................................................................................................................ 102 A Load Test Output ...................................................................................................................... ...................................................................................... 71 A Optional (Dual) Generator Model ......... .............................................................................................................................................................. ...................... Delphi AD244 Rated Output ......................................................................................... ....................................................................................................................... 130 A Load Test Output .................................................................................................................................................. .......................................................... 91 A Bosch® Generator Generator Model ............................... ....................................................................................................................................................... Bosch® 15755900 Rated Output ........................................................................................................ ........................................................................................................ 130 A Load Test Output ............. .............................................................................................................................................................. ................................. 91 A Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Amperage > Page 9263 Alternator: Specifications Voltage Voltage Charging Voltage 13-16 Volts Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 9264 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9267 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9268 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9269 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9270 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9271 Alternator: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9272 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9273 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9274 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9275 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9276 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9277 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9278 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9279 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9280 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9281 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9282 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9283 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9284 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9285 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9286 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9287 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9288 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9289 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9290 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9291 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9292 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9293 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9294 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9295 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9296 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9297 Generator Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 9298 Generator Usage Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 9299 Alternator: Description and Operation GENERATOR The AD-230 and AD-244 generators are non-repairable. They are electrically similar to earlier models. The generators feature the following major components: - The delta stator - The rectifier bridge - The rotor with slip rings and brushes - A conventional pulley - Dual internal fans - A voltage regulator The pulley and the fan cool the slip ring and the frame. The AD stands for Air-cooled Dual internal fan; the 2 is an electrical design designator; the 30/44 denotes the outside diameter of the stator laminations in millimeters, over 100 millimeters. The generators is rated at 102 and 130 amperes respectively. The generator features permanently lubricated bearings. Service should only include the tightening of mounting components. Otherwise, the generator is replaced as a complete unit. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement Alternator: Service and Repair Generator Bracket Replacement REMOVAL PROCEDURE 1. Remove the battery cable junction block bracket bolts. 2. Remove the generator. 3. Remove the power steering pump. 4. Remove the generator bracket bolts. 5. Remove the generator bracket. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9302 1. Install the generator bracket. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the generator bracket bolts. Tighten Tighten the generator bracket bolts to 50 N.m (37 lb ft). 3. Install the power steering pump. 4. Install the generator. 5. Install the battery cable junction block bracket bolts. Tighten Tighten the battery cable junction block bracket bolts to 9 N.m (80 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9303 Alternator: Service and Repair Generator Cable Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions 1. Disconnect the negative battery cable. 2. If necessary, remove the engine sight shield. 3. Remove the generator cable from the generator, perform the following: 3.1. Reposition the boot to expose the stud. 3.2. Remove the generator cable nut. 3.3. Remove the generator cable from the stud. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9304 4. Open the positive cable junction block. 5. Remove the generator cable nut. 6. Remove the generator cable (2) from the junction block. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the generator cable (2) to the junction block. 2. Install the generator cable nut. Tighten Tighten the generator cable nut to 9 N.m (80 lb in). 3. Close the positive cable junction block. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9305 4. Install the generator cable to the generator, perform the following: 4.1. Install the generator cable to the stud. 4.2. Install the generator cable nut. Tighten Tighten the generator cable nut to 9 N.m (80 lb in). 4.3. Position the boot to cover the stud. 5. If necessary, install the engine sight shield. 6. Connect the negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9306 Alternator: Service and Repair Generator Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the accessory drive belt. 3. If necessary, remove the engine sight shield. 4. Disconnect the generator electrical connector (3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9307 5. Remove the generator cable from the generator, perform the following: 5.1. Slide the boot down revealing the terminal stud. 5.2. Remove the generator cable nut from the terminal stud. 5.3. Remove the generator cable. 6. Remove the generator bolts. 7. Remove the generator. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9308 1. Install the generator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the generator bolts. Tighten Tighten the generator bolts to 50 N.m (37 lb ft). 3. Install the generator cable to the generator, perform the following: 3.1. Install the generator cable. 3.2. Install the generator cable nut to the terminal stud. Tighten Tighten the generator cable nut to 9 N.m (80 lb in). 3.3. Slide the boot over the terminal stud. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9309 4. Connect the generator electrical connector (3). 5. If necessary, install the engine sight shield. 6. Install the accessory drive belt. 7. Connect the negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Locations Ignition Lock: Locations For additional steering column components locations, Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 9323 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 9324 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 9325 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Heat Shield > Component Information > Service and Repair Starter Heat Shield: Service and Repair STARTER SHIELD REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter motor. 2. If equipped with a 4.8L, 5.3L, or 6.0L engine, remove the starter heat shield. 3. If equipped with a 8.1L engine, remove the starter heat shield bolts, and nut. 4. Remove the starter heat shield. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Heat Shield > Component Information > Service and Repair > Page 9330 1. If equipped with a 8.1L engine, install the starter heat shield. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the starter heat shield bolts, and nut. Tighten Tighten the starter heat shield bolts to 3 N.m (35 lb in). - Tighten the starter heat shield nut to 5 N.m (44 lb in). 3. If equipped with a 4.8L, 5.3L, or 6.0L engine, install the starter heat shield. 4. Install the starter motor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 9334 Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 9335 Starter Relay: Service and Repair REMOVAL PROCEDURE 1. Remove the underhood bussed electrical center (UBEC) cover. 2. Remove the starter motor relay. INSTALLATION PROCEDURE 1. Install the starter motor relay. 2. Install the underhood bussed electrical center (UBEC) cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Page 9343 Auxiliary Power Outlet: Diagrams Auxiliary Power Outlet Auxiliary Power Outlet - Rear Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Page 9344 Auxiliary Power Outlet - Console Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View Fuse: Locations Fuse Block - Underhood Connector View Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 9351 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 9352 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 9353 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 9354 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 9355 Fuse: Locations Fuse Block - Underhood Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 9356 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 9357 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood Fuse: Application and ID Fuse Block - Underhood Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9360 Fuse Application Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9361 Fuse Application Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9362 Fuse Block - Right I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9363 Fuse: Application and ID Fuse Block - Left I/P Fuse Block - Left I/P Fuse Block Fuse Applications Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9364 Fuse Block Fuse Applications Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Location Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 9369 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 9370 Fuse Block: Locations Fuse Block - Underhood Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 9371 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 9372 Fuse Block: Locations Fuse Block - Underhood Connector View Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 9373 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 9374 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 9375 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P Fuse Block: Diagrams Fuse Block - Left I/P Fuse Block - Left I/P Fuse Block Fuse Applications Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9378 Fuse Block Fuse Applications Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9379 Fuse Block - Right I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9380 Fuse Block: Diagrams Fuse Block - Underhood Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9381 Fuse Application Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9382 Fuse Application Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9383 Fuse Block: Diagrams Left I/P Fuse Block - Left I/P - C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9384 Fuse Block - Left I/P - C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9385 Fuse Block - Left I/P - C1 Part 3 Fuse Block - Left I/P - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9386 Fuse Block - Left I/P - C4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9387 Fuse Block - Left I/P - C6 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9388 Fuse Block: Diagrams Fuse Block - Left I/P Fuse Block Fuse Applications Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9389 Fuse Block Fuse Applications Part 2 Fuse Block - Right I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9390 Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9391 Fuse Application Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9392 Fuse Application Part 2 Left I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9393 Fuse Block - Left I/P - C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9394 Fuse Block - Left I/P - C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9395 Fuse Block - Left I/P - C1 Part 3 Fuse Block - Left I/P - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9396 Fuse Block - Left I/P - C4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9397 Fuse Block - Left I/P - C6 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Relay Block Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9398 Relay Block - Body - C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9399 Relay Block - Body - C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9400 Relay Block - Body - C1 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9401 Relay Block - Body - C2 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9402 Relay Block - Body - C2 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9403 Relay Block - Body - C2 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9404 Relay Block - Body - C4 Relay Block - Body - C5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9405 Relay Block - Body - C6 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9406 Relay Block - Body - C6 Part 2 Relay Block - Body - C8 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9407 Relay Block - Body - C9 Relay Block - Body - C10 Part 1 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9408 Relay Block - Body Right I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9409 Fuse Block - Right I/P - C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9410 Fuse Block - Right I/P - C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9411 Fuse Block - Right I/P - C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9412 Fuse Block - Right I/P - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9413 Fuse Block - Right I/P - C4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9414 Fuse Block - Right I/P - C5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9415 Fuse Block - Right I/P - C6 Fuse Block - Right I/P - C7 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9416 Fuse Block - Right I/P - C7 Part 2 Fuse Block - Right I/P - C8 Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9417 Relay Block - Underhood - C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9418 Relay Block - Underhood - C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9419 Relay Block - Underhood - C1 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9420 Relay Block - Underhood - C2 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9421 Relay Block - Underhood - C2 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9422 Relay Block - Underhood - C2 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9423 Relay Block - Underhood - C2 Part 4 Relay Block - Underhood - C3 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9424 Relay Block - Underhood - C3 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9425 Relay Block - Underhood - C4 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9426 Relay Block - Underhood - C4 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9427 Relay Block - Underhood - C4 Part 3 Relay Block - Underhood - C5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9428 Relay Block - Underhood - C6 Relay Block - Underhood - C7 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9429 Relay Block - Underhood - C8 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P Fuse Block: Application and ID Fuse Block - Left I/P Fuse Block - Left I/P Fuse Block Fuse Applications Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P > Page 9432 Fuse Block Fuse Applications Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P > Page 9433 Fuse Block - Right I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P > Page 9434 Fuse Block: Application and ID Fuse Block - Underhood Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P > Page 9435 Fuse Application Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P > Page 9436 Fuse Application Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9439 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the starting and charging center bracket remove the 4 retaining bolts (1). 10. Remove the starting and charging center bracket assembly from the fender. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9440 INSTALLATION PROCEDURE 1. Install the starting and charging center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9441 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9442 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9443 Fuse Block: Service and Repair I/P Electrical Center or Junction Block Replacement Left REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the left side end panel. 3. Press on the clips on the top and the bottom in order to remove the fuse block from the instrument panel (IP) assembly. 4. Disconnect all wiring connectors from the fuse block. 5. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Connect all wiring connectors to the fuse block. 2. Position the fuse block onto the IP assembly. 3. Press on the clips on the top and the bottom of the fuse block and push in the clips until seated. 4. Install the left side end panel. 5. Connect the negative battery cable(s). Right REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9444 CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the right side end panel. 3. Unclip the wiring connector(s) from the front of the Instrument Panel (IP) wiring harness junction block Unclip the harness from the fastener. 4. Remove the IP wiring harness junction block from the IP by pressing on both of the clips and pulling rearward. 5. Disconnect the lower IP light bulb by twisting the bulb counterclockwise and pulling the bulb rearward. 6. Feed the IP wiring harness junction block through the hole in the IP. 7. Disconnect all remaining wiring connectors from the rear of the IP wiring harness junction block. 8. Remove the IP wiring harness junction block from the vehicle. INSTALLATION PROCEDURE 1. Connect the wiring connectors to the rear of the IP wiring harness junction block. 2. Feed the IP wiring harness junction block through the hole in the IP. 3. Connect the lower IP light bulb by twisting the bulb socket clockwise while pushing in. 4. Connect the IP wiring harness junction block to the IP by pressing on both clips and pushing until sealed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9445 5. Connect the wiring connector(s) onto the front of the IP wiring harness junction block and connect the harness to the fastener. 6. Install the right side end panel. 7. Connect the negative battery cable(s). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9446 Fuse Block: Service and Repair Body Wiring Harness Junction Block Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the harness from the front of the body wiring harness junction block. 3. Unsnap the cover from the body wiring harness junction block. 4. Unsnap the top pivots and rotate the body wiring harness junction block (1) down. Unsnap the lower pivots and remove the body wiring harness junction block from the bracket (2). 5. Disconnect the two 68-way IP connectors. 6. Disconnect the remaining wiring connectors from the body wiring harness junction block. 7. Remove the body wiring harness junction block from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9447 1. Connect the two 68-way IP connectors to the body wiring harness junction block. 2. Connect all remaining wiring connectors. 3. Snap the body wiring harness junction block (1) onto the bracket (2). 4. Connect the harness to the front of the body wiring harness junction block. 5. Fasten the cover to the body wiring harness junction block. 6. Connect the negative battery cable(s). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > Customer Interest for Ground Strap: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Ground Strap: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > Customer Interest for Ground Strap: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 9456 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ground Strap: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Ground Strap: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ground Strap: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 9462 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > Page 9463 Ground Strap: Service and Repair GROUND STRAP REPLACEMENT REMOVAL PROCEDURE 1. If necessary, remove the engine sight shield. 2. Remove the engine wiring harness ground bolt. 3. Reposition the engine wiring harness ground and ground strap. 4. Remove the ground strap nut from the stud at the front of dash. 5. Remove the ground strap from the stud. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > Page 9464 1. Install the ground strap to the stud. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ground strap nut to the stud at the front of dash. Tighten Tighten the ground strap nut to 9 N.m (80 lb in). 3. Position the ground strap and engine wiring harness ground. 4. Install the engine wiring harness ground bolt. Tighten Tighten the engine wiring harness ground bolt to 16 N.m (12 lb ft). 5. If necessary, install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 9473 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9479 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9480 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9481 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9482 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9483 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9484 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 9489 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9495 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9496 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9497 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9498 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9499 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9500 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 Multiple Junction Connector: Diagrams C100 - C199 C100 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9505 C102 C103 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9506 C103 Part 2 C104 Z75 Only C104 Z75 Only Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9507 C104 Z75 Only Part 2 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes C114 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9508 C114 Part 2 C117 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9509 C118 C125 Snowplow Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9510 C127 Snowplow C148 Odd Ignition Coils Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9511 C148 Odd Ignition Coils Part 2 C149 Even Ignition Coils Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9512 C150 4WD JMPR C151 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9513 C152 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9514 C153 C154 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9515 C198 H.D. Trailer Wiring C199 Camper Wiring Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9516 Multiple Junction Connector: Diagrams C200 - C299 C200 C200 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9517 C200 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9518 C200 Part 3 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes C201 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9519 C201 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9520 C201 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9521 C202 C204 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9522 C204 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes C205 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9523 C205 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9524 C206 C207 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9525 C207 Part 2 C208 C208 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9526 C208 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9527 C208 Part 3 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9528 C209 (806) C210 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9529 C211 C212 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9530 C212 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9531 C212 Part 2 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9532 C216 C217 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9533 C218 C248 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9534 C248 Part 2 C249 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9535 C251 C252 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9536 C253 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9537 C254 C290 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9538 C290 Part 2 C296 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9539 C296 Part 2 C298 C299 Uplevel Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9540 C299 Uplevel Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9541 C299 Uplevel Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9542 C299 Uplevel Part 3 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9543 Multiple Junction Connector: Diagrams C303 - C399 C303 Connection To Seat Harness Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9544 C305 Connection To Seat Harness C306 Y91/Z75 C306 Y91/Z75 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9545 C306 Y91/Z75 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9546 C306 Y91/Z75 Part 3 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9547 C307 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9548 C310 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9549 C312 C313 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9550 C313 Part 2 C314 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9551 C314 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9552 C314 Part 3 C315 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9553 C320 C321 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9554 C321 Part 2 C322 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9555 C322 Part 2 C323 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9556 C323 Part 2 C324 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9557 C325 C326 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9558 C327 Seat Harness Connector Luxury C328 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9559 C330 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9560 C330 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9561 C340 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9562 C340 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9563 C341 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9564 C349 C350 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9565 C350 Part 2 C351 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9566 C353 C387 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9567 C388 C389 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9568 C390 C395 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9569 C396 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9570 C396 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9571 C397 C398 Connection To Seat Harness C399 Connection To Seat Harness Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9572 Multiple Junction Connector: Diagrams C402 - C499 C402 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9573 C403 C404 C405 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9574 C406 Part 1 C406 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9575 C450 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9576 C450 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9577 C450 Part 3 C495 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9578 C497 - Luxury Utility Part 1 C497 - Luxury Utility Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9579 C499 Part 1 C499 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9580 Multiple Junction Connector: Diagrams C900 - C901 C900 C901 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation BATTERY RUNDOWN PROTECTION/INADVERTENT POWER In the event that any of the interior lamps supplied voltage by the inadvertent power relay and ground from the courtesy lamp relay were to remain on when the ignition is OFF after a period of 20 minutes, the BCM will deactivate the inadvertent power relay turning OFF all of the lamps on that circuit to prevent total battery discharge. Only when the ignition switch is cycled back to the RUN position will the BCM reset the internal timer and reactivate the inadvertent power relay. When the inadvertent power relay is not energized, the BCM utilizes the inadvertent power courtesy lamp supply voltage circuit to monitor for a courtesy lamp switch request signal. If a courtesy lamp switch is activated, the BCM will receive the signal to energize the inadvertent power relay by grounding the control circuit. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 9588 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Junction Block - Rear Lamps - C2 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 9589 Junction Block - Rear Lamps - C2 Part 2 Junction Block - Rear Lamps - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 9590 Junction Block - Rear Lamps - C4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) Relay Box: Service and Repair Relay Replacement (Within an Electrical Center) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views to locate the electrical center where the relay exists. IMPORTANT: Always note the orientation of the relay. - Make sure the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). NOTE: Use J 43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 9593 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 9594 Relay Box: Service and Repair Relay Replacement (Attached to Wire Harness) REMOVAL PROCEDURE 1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. IMPORTANT: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). INSTALLATION PROCEDURE 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 9598 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Junction Block - Rear Lamps - C2 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 9599 Junction Block - Rear Lamps - C2 Part 2 Junction Block - Rear Lamps - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 9600 Junction Block - Rear Lamps - C4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) Relay Box: Service and Repair Relay Replacement (Within an Electrical Center) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views to locate the electrical center where the relay exists. IMPORTANT: Always note the orientation of the relay. - Make sure the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). NOTE: Use J 43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 9603 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 9604 Relay Box: Service and Repair Relay Replacement (Attached to Wire Harness) REMOVAL PROCEDURE 1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. IMPORTANT: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). INSTALLATION PROCEDURE 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation BATTERY RUNDOWN PROTECTION/INADVERTENT POWER In the event that any of the interior lamps supplied voltage by the inadvertent power relay and ground from the courtesy lamp relay were to remain on when the ignition is OFF after a period of 20 minutes, the BCM will deactivate the inadvertent power relay turning OFF all of the lamps on that circuit to prevent total battery discharge. Only when the ignition switch is cycled back to the RUN position will the BCM reset the internal timer and reactivate the inadvertent power relay. When the inadvertent power relay is not energized, the BCM utilizes the inadvertent power courtesy lamp supply voltage circuit to monitor for a courtesy lamp switch request signal. If a courtesy lamp switch is activated, the BCM will receive the signal to energize the inadvertent power relay by grounding the control circuit. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9617 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9618 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9619 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9625 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9626 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9627 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9632 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9633 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9634 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9635 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9636 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9637 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 9642 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9648 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9649 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9650 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9651 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9652 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9653 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 9658 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Page 9663 Auxiliary Power Outlet: Diagrams Auxiliary Power Outlet Auxiliary Power Outlet - Rear Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Page 9664 Auxiliary Power Outlet - Console Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View Fuse: Locations Fuse Block - Underhood Connector View Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 9671 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 9672 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 9673 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 9674 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 9675 Fuse: Locations Fuse Block - Underhood Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 9676 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - Underhood Connector View > Page 9677 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood Fuse: Application and ID Fuse Block - Underhood Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9680 Fuse Application Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9681 Fuse Application Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9682 Fuse Block - Right I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9683 Fuse: Application and ID Fuse Block - Left I/P Fuse Block - Left I/P Fuse Block Fuse Applications Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9684 Fuse Block Fuse Applications Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Location Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 9689 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 9690 Fuse Block: Locations Fuse Block - Underhood Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 9691 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 9692 Fuse Block: Locations Fuse Block - Underhood Connector View Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 9693 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 9694 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Location > Page 9695 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P Fuse Block: Diagrams Fuse Block - Left I/P Fuse Block - Left I/P Fuse Block Fuse Applications Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9698 Fuse Block Fuse Applications Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9699 Fuse Block - Right I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9700 Fuse Block: Diagrams Fuse Block - Underhood Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9701 Fuse Application Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9702 Fuse Application Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9703 Fuse Block: Diagrams Left I/P Fuse Block - Left I/P - C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9704 Fuse Block - Left I/P - C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9705 Fuse Block - Left I/P - C1 Part 3 Fuse Block - Left I/P - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9706 Fuse Block - Left I/P - C4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9707 Fuse Block - Left I/P - C6 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9708 Fuse Block: Diagrams Fuse Block - Left I/P Fuse Block Fuse Applications Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9709 Fuse Block Fuse Applications Part 2 Fuse Block - Right I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9710 Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9711 Fuse Application Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9712 Fuse Application Part 2 Left I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9713 Fuse Block - Left I/P - C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9714 Fuse Block - Left I/P - C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9715 Fuse Block - Left I/P - C1 Part 3 Fuse Block - Left I/P - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9716 Fuse Block - Left I/P - C4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9717 Fuse Block - Left I/P - C6 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Relay Block Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9718 Relay Block - Body - C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9719 Relay Block - Body - C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9720 Relay Block - Body - C1 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9721 Relay Block - Body - C2 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9722 Relay Block - Body - C2 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9723 Relay Block - Body - C2 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9724 Relay Block - Body - C4 Relay Block - Body - C5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9725 Relay Block - Body - C6 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9726 Relay Block - Body - C6 Part 2 Relay Block - Body - C8 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9727 Relay Block - Body - C9 Relay Block - Body - C10 Part 1 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9728 Relay Block - Body Right I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9729 Fuse Block - Right I/P - C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9730 Fuse Block - Right I/P - C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9731 Fuse Block - Right I/P - C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9732 Fuse Block - Right I/P - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9733 Fuse Block - Right I/P - C4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9734 Fuse Block - Right I/P - C5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9735 Fuse Block - Right I/P - C6 Fuse Block - Right I/P - C7 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9736 Fuse Block - Right I/P - C7 Part 2 Fuse Block - Right I/P - C8 Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9737 Relay Block - Underhood - C1 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9738 Relay Block - Underhood - C1 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9739 Relay Block - Underhood - C1 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9740 Relay Block - Underhood - C2 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9741 Relay Block - Underhood - C2 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9742 Relay Block - Underhood - C2 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9743 Relay Block - Underhood - C2 Part 4 Relay Block - Underhood - C3 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9744 Relay Block - Underhood - C3 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9745 Relay Block - Underhood - C4 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9746 Relay Block - Underhood - C4 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9747 Relay Block - Underhood - C4 Part 3 Relay Block - Underhood - C5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9748 Relay Block - Underhood - C6 Relay Block - Underhood - C7 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Fuse Block - Left I/P > Page 9749 Relay Block - Underhood - C8 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P Fuse Block: Application and ID Fuse Block - Left I/P Fuse Block - Left I/P Fuse Block Fuse Applications Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P > Page 9752 Fuse Block Fuse Applications Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P > Page 9753 Fuse Block - Right I/P Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P > Page 9754 Fuse Block: Application and ID Fuse Block - Underhood Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P > Page 9755 Fuse Application Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Left I/P > Page 9756 Fuse Application Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9759 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the starting and charging center bracket remove the 4 retaining bolts (1). 10. Remove the starting and charging center bracket assembly from the fender. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9760 INSTALLATION PROCEDURE 1. Install the starting and charging center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9761 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9762 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9763 Fuse Block: Service and Repair I/P Electrical Center or Junction Block Replacement Left REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the left side end panel. 3. Press on the clips on the top and the bottom in order to remove the fuse block from the instrument panel (IP) assembly. 4. Disconnect all wiring connectors from the fuse block. 5. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Connect all wiring connectors to the fuse block. 2. Position the fuse block onto the IP assembly. 3. Press on the clips on the top and the bottom of the fuse block and push in the clips until seated. 4. Install the left side end panel. 5. Connect the negative battery cable(s). Right REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9764 CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the right side end panel. 3. Unclip the wiring connector(s) from the front of the Instrument Panel (IP) wiring harness junction block Unclip the harness from the fastener. 4. Remove the IP wiring harness junction block from the IP by pressing on both of the clips and pulling rearward. 5. Disconnect the lower IP light bulb by twisting the bulb counterclockwise and pulling the bulb rearward. 6. Feed the IP wiring harness junction block through the hole in the IP. 7. Disconnect all remaining wiring connectors from the rear of the IP wiring harness junction block. 8. Remove the IP wiring harness junction block from the vehicle. INSTALLATION PROCEDURE 1. Connect the wiring connectors to the rear of the IP wiring harness junction block. 2. Feed the IP wiring harness junction block through the hole in the IP. 3. Connect the lower IP light bulb by twisting the bulb socket clockwise while pushing in. 4. Connect the IP wiring harness junction block to the IP by pressing on both clips and pushing until sealed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9765 5. Connect the wiring connector(s) onto the front of the IP wiring harness junction block and connect the harness to the fastener. 6. Install the right side end panel. 7. Connect the negative battery cable(s). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9766 Fuse Block: Service and Repair Body Wiring Harness Junction Block Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the harness from the front of the body wiring harness junction block. 3. Unsnap the cover from the body wiring harness junction block. 4. Unsnap the top pivots and rotate the body wiring harness junction block (1) down. Unsnap the lower pivots and remove the body wiring harness junction block from the bracket (2). 5. Disconnect the two 68-way IP connectors. 6. Disconnect the remaining wiring connectors from the body wiring harness junction block. 7. Remove the body wiring harness junction block from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9767 1. Connect the two 68-way IP connectors to the body wiring harness junction block. 2. Connect all remaining wiring connectors. 3. Snap the body wiring harness junction block (1) onto the bracket (2). 4. Connect the harness to the front of the body wiring harness junction block. 5. Fasten the cover to the body wiring harness junction block. 6. Connect the negative battery cable(s). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > Customer Interest for Ground Strap: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Ground Strap: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > Customer Interest for Ground Strap: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 9776 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ground Strap: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Ground Strap: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ground Strap: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 9782 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > Page 9783 Ground Strap: Service and Repair GROUND STRAP REPLACEMENT REMOVAL PROCEDURE 1. If necessary, remove the engine sight shield. 2. Remove the engine wiring harness ground bolt. 3. Reposition the engine wiring harness ground and ground strap. 4. Remove the ground strap nut from the stud at the front of dash. 5. Remove the ground strap from the stud. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Technical Service Bulletins > Page 9784 1. Install the ground strap to the stud. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ground strap nut to the stud at the front of dash. Tighten Tighten the ground strap nut to 9 N.m (80 lb in). 3. Position the ground strap and engine wiring harness ground. 4. Install the engine wiring harness ground bolt. Tighten Tighten the engine wiring harness ground bolt to 16 N.m (12 lb ft). 5. If necessary, install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 9793 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 9799 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 9800 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 9801 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 9802 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 9803 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 9804 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 9809 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9815 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9816 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9817 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9818 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9819 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9820 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 Multiple Junction Connector: Diagrams C100 - C199 C100 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9825 C102 C103 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9826 C103 Part 2 C104 Z75 Only C104 Z75 Only Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9827 C104 Z75 Only Part 2 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes C114 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9828 C114 Part 2 C117 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9829 C118 C125 Snowplow Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9830 C127 Snowplow C148 Odd Ignition Coils Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9831 C148 Odd Ignition Coils Part 2 C149 Even Ignition Coils Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9832 C150 4WD JMPR C151 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9833 C152 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9834 C153 C154 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9835 C198 H.D. Trailer Wiring C199 Camper Wiring Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9836 Multiple Junction Connector: Diagrams C200 - C299 C200 C200 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9837 C200 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9838 C200 Part 3 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes C201 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9839 C201 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9840 C201 Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9841 C202 C204 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9842 C204 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes C205 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9843 C205 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9844 C206 C207 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9845 C207 Part 2 C208 C208 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9846 C208 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9847 C208 Part 3 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9848 C209 (806) C210 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9849 C211 C212 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9850 C212 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9851 C212 Part 2 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9852 C216 C217 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9853 C218 C248 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9854 C248 Part 2 C249 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9855 C251 C252 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9856 C253 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9857 C254 C290 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9858 C290 Part 2 C296 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9859 C296 Part 2 C298 C299 Uplevel Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9860 C299 Uplevel Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9861 C299 Uplevel Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9862 C299 Uplevel Part 3 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9863 Multiple Junction Connector: Diagrams C303 - C399 C303 Connection To Seat Harness Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9864 C305 Connection To Seat Harness C306 Y91/Z75 C306 Y91/Z75 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9865 C306 Y91/Z75 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9866 C306 Y91/Z75 Part 3 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9867 C307 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9868 C310 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9869 C312 C313 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9870 C313 Part 2 C314 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9871 C314 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9872 C314 Part 3 C315 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9873 C320 C321 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9874 C321 Part 2 C322 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9875 C322 Part 2 C323 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9876 C323 Part 2 C324 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9877 C325 C326 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9878 C327 Seat Harness Connector Luxury C328 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9879 C330 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9880 C330 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9881 C340 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9882 C340 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9883 C341 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9884 C349 C350 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9885 C350 Part 2 C351 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9886 C353 C387 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9887 C388 C389 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9888 C390 C395 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9889 C396 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9890 C396 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9891 C397 C398 Connection To Seat Harness C399 Connection To Seat Harness Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9892 Multiple Junction Connector: Diagrams C402 - C499 C402 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9893 C403 C404 C405 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9894 C406 Part 1 C406 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9895 C450 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9896 C450 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9897 C450 Part 3 C495 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9898 C497 - Luxury Utility Part 1 C497 - Luxury Utility Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9899 C499 Part 1 C499 Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 9900 Multiple Junction Connector: Diagrams C900 - C901 C900 C901 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation BATTERY RUNDOWN PROTECTION/INADVERTENT POWER In the event that any of the interior lamps supplied voltage by the inadvertent power relay and ground from the courtesy lamp relay were to remain on when the ignition is OFF after a period of 20 minutes, the BCM will deactivate the inadvertent power relay turning OFF all of the lamps on that circuit to prevent total battery discharge. Only when the ignition switch is cycled back to the RUN position will the BCM reset the internal timer and reactivate the inadvertent power relay. When the inadvertent power relay is not energized, the BCM utilizes the inadvertent power courtesy lamp supply voltage circuit to monitor for a courtesy lamp switch request signal. If a courtesy lamp switch is activated, the BCM will receive the signal to energize the inadvertent power relay by grounding the control circuit. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 9908 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Junction Block - Rear Lamps - C2 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 9909 Junction Block - Rear Lamps - C2 Part 2 Junction Block - Rear Lamps - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 9910 Junction Block - Rear Lamps - C4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) Relay Box: Service and Repair Relay Replacement (Within an Electrical Center) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views to locate the electrical center where the relay exists. IMPORTANT: Always note the orientation of the relay. - Make sure the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). NOTE: Use J 43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 9913 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 9914 Relay Box: Service and Repair Relay Replacement (Attached to Wire Harness) REMOVAL PROCEDURE 1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. IMPORTANT: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). INSTALLATION PROCEDURE 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 9918 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Junction Block - Rear Lamps - C2 Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 9919 Junction Block - Rear Lamps - C2 Part 2 Junction Block - Rear Lamps - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 9920 Junction Block - Rear Lamps - C4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) Relay Box: Service and Repair Relay Replacement (Within an Electrical Center) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views to locate the electrical center where the relay exists. IMPORTANT: Always note the orientation of the relay. - Make sure the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). NOTE: Use J 43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 9923 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 9924 Relay Box: Service and Repair Relay Replacement (Attached to Wire Harness) REMOVAL PROCEDURE 1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. IMPORTANT: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). INSTALLATION PROCEDURE 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation BATTERY RUNDOWN PROTECTION/INADVERTENT POWER In the event that any of the interior lamps supplied voltage by the inadvertent power relay and ground from the courtesy lamp relay were to remain on when the ignition is OFF after a period of 20 minutes, the BCM will deactivate the inadvertent power relay turning OFF all of the lamps on that circuit to prevent total battery discharge. Only when the ignition switch is cycled back to the RUN position will the BCM reset the internal timer and reactivate the inadvertent power relay. When the inadvertent power relay is not energized, the BCM utilizes the inadvertent power courtesy lamp supply voltage circuit to monitor for a courtesy lamp switch request signal. If a courtesy lamp switch is activated, the BCM will receive the signal to energize the inadvertent power relay by grounding the control circuit. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9937 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9938 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9939 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9945 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9946 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9947 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9952 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9953 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9954 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9955 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9956 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9957 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 9962 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9968 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9969 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9970 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9971 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9972 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9973 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 9978 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 9984 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 9985 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 9986 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 9987 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 9988 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 9989 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 9990 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 9991 Alignment: Technical Service Bulletins Steering/Suspension - Revised Caster/Camber Adjustment Info - Revised Front Caster and Camber Adjustment Procedure # 02-03-07-002A - (Mar 24, 2005) Models: 1999-2000 Cadillac Escalade 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Express, Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999 GMC Suburban 1999-2005 GMC Savana, Sierra, Yukon, Yukon XL, Yukon XL Denali This bulletin is being revised to add model years and clarify the information. Please discard Corporate Bulletin Number 02-03-07-002 (Section 03 - Suspension). When performing a wheel alignment on any of the above vehicles, please refer to the Front Caster and Camber Adjustment Procedure in SI before contacting the GM Technical Assistance Center (TAC) with issues concerning adjustments, caster out-of-spec, etc. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Ride/Trim Height Inspection Procedure Alignment: Specifications Ride/Trim Height Inspection Procedure Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: 1. Set the tire pressures to the pressure shown on the certification label. 2. Check the fuel level. Add additional weight if necessary to simulate a full tank. 3. Make sure the rear compartment is empty except for the spare tire. 4. Make sure the vehicle is on a level surface, such as an alignment rack. 5. Close the doors. 6. Close the hood. 7. All dimensions are measured vertical to the ground. Trim heights should be within 13 mm (0.5 inch) to be considered correct. Z Height Measurement Important: K models only the Z height must be adjusted before the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use an adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Lift the front bumper of the vehicle up about 38 mm (1.5 inch). 2. Gently remove your hands. 3. Allow the vehicle to settle into position. 4. Repeat this jouncing operation 2 more times for a total of 3 times. 5. Measure from the pivot bolt center line (3) down to the lower corner (5) of the lower ball joint (1) in order to obtain the Z height measurement (4). 6. Push the front bumper of the vehicle down about 38 mm (1.5 inch). 7. Gently remove your hands. 8. Allow the vehicle to rise. 9. Repeat the operation for a total of 3 times. 10. Measure the Z dimension. 11. The true Z height dimension number is the average of the high and the low measurements. Z Height Adjustment Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Ride/Trim Height Inspection Procedure > Page 9994 1. For vehicles equipped with a torsion bar suspension turn the bolt (1) that contacts the torsion arm clockwise to raise the and counterclockwise to lower the height adjustment. One revolution of the bolt (1) into the nut increases the Z height by approximately 6.0 mm (0.2 inch). 2. For vehicles without torsion bars, replace damaged or worn components as necessary. D Height Measurement The D height dimension measurement determines the proper rear end ride height. There is no adjustment procedure. Repair may require replacement of suspension components. 1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 inch). 2. Gently remove your hands. Allow the vehicle to settle into position. 3. Repeat the jouncing operation 2 more times for a total of 3 times. 4. Measure the D height by measuring the distance between the bumper bracket and the top of the rear axle tube. 5. Push the rear bumper downward to 38 mm (1.5 inch). 6. Gently remove your hands. Allow the vehicle to settle into position. 7. Repeat the jouncing operation 2 more times for a total of 3 times. 8. Measure the D height dimension. 9. The true D height dimension number is the average of the high and the low measurements. 10. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging front suspension ^ Sagging rear leaf/coil springs ^ Worn rear suspension components, such as leaf spring bushings ^ Improper tire inflation ^ Improper weight distribution ^ Collision damage Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Ride/Trim Height Inspection Procedure > Page 9995 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Ride/Trim Height Inspection Procedure > Page 9996 Alignment: Specifications Wheel Alignment Specifications Alignment Wheel Alignment Specifications Fastener Tightening Specifications Trim Height Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 9997 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear and is not adjustable on this vehicle. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 9998 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Lead/pull is the deviation of the vehicle from a straight path, on a level road, without hand pressure on the steering wheel. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Uneven brake adjustment ^ Wheel alignment The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 9999 Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Alignment: Service and Repair Trim Height Inspection Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: 1. Set the tire pressures to the pressure shown on the certification label. 2. Check the fuel level. Add additional weight if necessary to simulate a full tank. 3. Make sure the rear compartment is empty except for the spare tire. 4. Make sure the vehicle is on a level surface, such as an alignment rack. 5. Close the doors. 6. Close the hood. 7. All dimensions are measured vertical to the ground. Trim heights should be within 13 mm (0.5 inch) to be considered correct. Z Height Measurement Important: K models only the Z height must be adjusted before the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use an adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Lift the front bumper of the vehicle up about 38 mm (1.5 inch). 2. Gently remove your hands. 3. Allow the vehicle to settle into position. 4. Repeat this jouncing operation 2 more times for a total of 3 times. 5. Measure from the pivot bolt center line (3) down to the lower corner (5) of the lower ball joint (1) in order to obtain the Z height measurement (4). 6. Push the front bumper of the vehicle down about 38 mm (1.5 inch). 7. Gently remove your hands. 8. Allow the vehicle to rise. 9. Repeat the operation for a total of 3 times. 10. Measure the Z dimension. 11. The true Z height dimension number is the average of the high and the low measurements. Z Height Adjustment Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 10002 1. For vehicles equipped with a torsion bar suspension turn the bolt (1) that contacts the torsion arm clockwise to raise the and counterclockwise to lower the height adjustment. One revolution of the bolt (1) into the nut increases the Z height by approximately 6.0 mm (0.2 inch). 2. For vehicles without torsion bars, replace damaged or worn components as necessary. D Height Measurement The D height dimension measurement determines the proper rear end ride height. There is no adjustment procedure. Repair may require replacement of suspension components. 1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 inch). 2. Gently remove your hands. Allow the vehicle to settle into position. 3. Repeat the jouncing operation 2 more times for a total of 3 times. 4. Measure the D height by measuring the distance between the bumper bracket and the top of the rear axle tube. 5. Push the rear bumper downward to 38 mm (1.5 inch). 6. Gently remove your hands. Allow the vehicle to settle into position. 7. Repeat the jouncing operation 2 more times for a total of 3 times. 8. Measure the D height dimension. 9. The true D height dimension number is the average of the high and the low measurements. 10. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging front suspension ^ Sagging rear leaf/coil springs ^ Worn rear suspension components, such as leaf spring bushings ^ Improper tire inflation ^ Improper weight distribution ^ Collision damage Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 10003 Alignment: Service and Repair Measuring Wheel Alignment Measuring Wheel Alignment Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. Refer to Tire Inflation Pressure Specifications and Tire Diagnosis - Irregular or Premature Wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. ^ Inspect the vehicle trim height. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 10004 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Front Caster and Camber Adjustment 1. Determine if the vehicle is relative to frame or relative to ground. If caster is relative to frame, the caster values must be compensated for the measured frame angle. To determine the frame angle use a digital protractor or equivalent. 2. Frame angle is positive when higher in the rear. Measure both sides of the frame and take an average from those measurements. Then add the average frame angle to the caster reading obtained in step 5 of this procedure when making adjustments. 3. Frame angle is negative when lower in the rear. Measure both sides of the frame and take an average from the measurements. Then subtract the average frame angle from the caster reading obtained in step 5 of this procedure when making adjustments. 4. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Important: Before adjusting the caster and camber angles, jounce the front bumper three times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. 5. For an accurate reading, do not push or pull on the tires during the alignment process. 6. Determine the caster angle (2). Be sure to compensate for frame angle where required. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 10005 7. Determine the positive camber (2) or negative camber (3) angle. 8. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 9. Loosen the upper control arm cam adjustment bolts. Notice: Refer to Fastener Notice in Service Precautions. 10. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met. When the adjustments are complete, hold the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. Tighten the cam nuts to 190 Nm (140 ft. lbs.). 11. Verify that the caster and the camber are still within specifications. When the caster and camber are within specifications, adjust the toe. Front Wheel Toe Adjustment Front Toe Adjustment Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 10006 1. Loosen the jam nut on the tie rod (2). 2. Rotate the inner tie rod (1) to the required toe specification setting. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the jam nut on the tie rod. Tighten the tie rod jam to 68 Nm (50 ft. lbs.). 4. Check the toe seeing after tightening. 5. Re-adjust the toe setting if necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Electronic Suspension Control Module to Bracket .............................................................................................................................. 1.6 Nm (14 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > C1 > Page 10014 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > C1 > Page 10015 Suspension Control Module: Diagrams C3 Suspension Control Module - C3 Part 1 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > C1 > Page 10016 Part 2 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > Page 10017 Suspension Control Module: Service and Repair Electronic Suspension Control Module Replacement (Tahoe/Yukon/Escalade) Removal Procedure 1. Remove the right side interior trim panel. 2. Disconnect the electrical connectors from the module. 3. Remove the screw. 4. Slide the module from the bracket and remove the module from the vehicle. Installation Procedure 1. Install the module to the vehicle by sliding the module into the bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screw. Tighten the screw to 1.6 Nm (14 inch lbs.). 3. Connect the electrical connectors to the module. 4. If you are replacing the module you must recalibrate the module by performing the following procedure: ^ Connect the scan tool to the Data Line Connector (DLC). ^ Turn the ignition ON with the engine OFF. ^ Proceed per the instructions on the scan tool readout. 5. Install the right side interior trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Steering Wheel Speed/Position Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Steering Wheel Speed/Position Sensor - W/ RTD Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Steering Wheel Speed/Position Sensor - W/ RTD > Page 10030 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Page 10031 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Removal Procedure 1. Set the front wheels in the straight-ahead position. Set the steering wheel in the LOCKED position. 2. Disable the Supplemental Inflatable Restraint (SIR). 3. Remove the nut and the bolt (1) from the upper intermediate shaft connection and slide the intermediate steering shaft down. 4. Remove the position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. Important: Do not apply force to the sensor and the bearing in a sideways direction. 5. Remove the position sensor and bearing assembly from the steering column jacket by pulling the assembly straight out. 6. Remove the position sensor from the clips in the bearing assembly. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Page 10032 1. Install the position sensor into the bearing assembly. Important: Do not apply force to the sensor and the bearing in a sideways direction. 2. Install the bearing into the steering column jacket. 2.1. Align the notches on the bearing and the column jacket. 2.2. Seat the bearing fulling into the jacket. 3. Connect the position sensor connector. Notice: Refer to Fastener Notice in Service Precautions. 4. Slide the shaft up to install the bolt and the nut (1) to the upper intermediate shaft to steering column connection. Tighten the upper intermediate shaft connection to 47 Nm (35 ft. lbs.). 5. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures Steering Column Position Sensor: Technical Service Bulletins Steering - Revised Service Procedures Bulletin No.: 03-02-36-002 Date: July 30, 2003 SERVICE MANUAL UPDATE Subject: Revised Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Procedure and Steering Wheel Position Sensor Centering Procedure Models: 1998-2003 Buick LeSabre, Park Avenue 1998-2003 Cadillac DeVille, Seville 2003 Cadillac CTS 1998-2003 Chevrolet Corvette 1998 Oldsmobile Achieva 1998-2002 Oldsmobile Intrigue 1998-2003 Oldsmobile Aurora 1999-2003 Oldsmobile Alero 1998-2003 Pontiac Bonneville, Grand Am 1998-2000 Chevrolet C/K Pickup Models 1998-2003 Chevrolet Suburban, Tahoe 1999-2003 Chevrolet Silverado 2002-2003 Chevrolet Avalanche 1998-1999 GMC Suburban 1998-2000 GMC C/K Pickup Models 1998-2003 GMC Yukon 1999-2003 GMC Sierra 2000-2003 GMC Yukon Denali, Yukon XL 2003 GMC Sierra Denali This bulletin is being issued to revise the Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement procedure in the Variable Effort Steering (1998-2001 model years) or Steering Wheel and Column (2002-2003 model years) and add the Steering Wheel Position Sensor Centering procedure in the Steering Wheel and Column sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Removal Procedure Caution: Refer to SIR Caution in Cautions and Notices. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. 2. Remove the steering column from the vehicle. Refer to Steering Column Replacement. 3. Remove the following from the steering shaft: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10037 3.1. steering shaft seal (7) 3.2. sensor retainer (6) 3.3. steering wheel position sensor (5), refer to Steering Wheel Position Sensor Centering. 3.4. 2 lower spring retainers (4) 3.5. lower bearing spring (3) 3.6. lower bearing seat (2) 3.7. adapter and bearing assembly (1) Installation Procedure 1. Install the following onto the steering shaft: 1.1. adapter and bearing assembly (1) 1.2. lower bearing seat (2) 1.3. lower bearing spring (3) 1.4. 2 lower spring retainers (4) 1.5. steering wheel position sensor (5) refer to Steering Wheel Position Sensor Centering. 1.6. sensor retainer (6) 1.7. steering shaft seal (7) 1.8. Enable the SIR system. Refer to in SIR. 2. Install the steering column to the vehicle. Refer to Steering Column Replacement. 3. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations below BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10038 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin (note location of the pin hole) ^ A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10039 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation section. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10040 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation section. 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation section. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10041 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin (note location of the pin hole) ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly. ^ A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10042 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats(1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10043 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10044 Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10045 Steering Column Position Sensor: Service and Repair This article has been updated with TSB# 03-02-36-002 REVISED STEERING WHEEL POSITION SENSOR OR STEERING SHAFT LOWER BEARING REPLACEMENT PROCEDURE AND STEERING WHEEL POSITION SENSOR CENTERING PROCEDURE STEERING WHEEL POSITION SENSOR OR STEERING SHAFT LOWER BEARING REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Cautions and Notices. 1. Disable the SIR system. 2. Remove the steering column from the vehicle. 3. Remove the following from the steering shaft: A. steering shaft seal (7) B. sensor retainer (6) C. steering wheel position sensor (5), refer to Steering Wheel Position Sensor Centering. D. two lower spring retainers (4) E. lower bearing spring (3) F. lower bearing seat (2) G. adapter and bearing assembly (1) INSTALLATION PROCEDURE 1. Install the following onto the steering shaft: A. adapter and bearing assembly (1) B. lower bearing seat (2) C. lower bearing spring (3) D. 2 lower spring retainers (4) E. steering wheel position sensor (5) refer to Steering Wheel Position Sensor Centering. F. sensor retainer (6) G. steering shaft seal (7) H. Enable the SIR system. 2. Install the steering column to the vehicle. 3. Enable the SIR system. STEERING WHEEL POSITION SENSOR CENTERING REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10046 IMPORTANT: Identify the type of steering wheel position sensor from the illustrations below BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. IMPORTANT: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin (note location of the pin hole) ^ A flush rotor flange cuff (4) IMPORTANT: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation section. 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10047 ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation section. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation section. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation section. 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin (note location of the pin hole) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10048 ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation section. INSTALLATION PROCEDURE IMPORTANT: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin (note location of the pin hole) ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly. ^ A view of the inside of the connector IMPORTANT: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT: If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10049 ^ An alignment tab (2) for installing into the adapter and bearing assembly. IMPORTANT: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT: If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. IMPORTANT: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT:If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. IMPORTANT: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT:If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10050 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. IMPORTANT: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT: If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications Ride Height Sensor: Specifications Front Position Sensor Link Bracket Bolt ................................................................................................................................................. 9 Nm (80 inch lbs.) Front Position Sensor Mounting Bolt .................................................................................................................................................. 12 Nm (106 inch lbs.) Rear Position Sensor Link Bracket Bolt ................................................................................................................................................... 25 Nm (18 ft. lbs.) Rear Position Sensor Mounting Bolt ................................................................................................................................................... 12 Nm (106 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Diagrams > LF Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Diagrams > LF > Page 10057 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Diagrams > LF > Page 10058 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Diagrams > LF > Page 10059 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Front Position Sensor Link Assembly Replacement - Electronic Suspension Ride Height Sensor: Service and Repair Front Position Sensor Link Assembly Replacement Electronic Suspension Front Position Sensor Link Assembly Replacement - Electronic Suspension Tools Required ^ J38185 Spring Hose Clamp Pliers Removal Procedure Important: Do not attempt to pry the link rod from the Real Time Damping (RTD) ball stud. If the link rod needs to be replaced or disconnected you must use the following procedure. 1. Remove the RTD sensor from the vehicle. 2. While supporting the sensor lever by hand, twist the link rod to remove it from the ball stud. 3. Remove the link rod from the mounting bracket ball stud. Installation Procedure 1. Using the J38185 install to link rod to the ball stud on the sensor lever and the mounting bracket. 2. Install the RTD sensor to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Front Position Sensor Link Assembly Replacement - Electronic Suspension > Page 10062 Ride Height Sensor: Service and Repair Rear Position Sensor Link Assembly Replacement Electronic Suspension Rear Position Sensor Link Assembly Replacement - Electronic Suspension Tools Required ^ J38185 Spring Hose Clamp Pliers Removal Procedure Important: Do not attempt to pry the link rod from the Real Time Damping (RTD) ball stud. If the link rod needs to be replaced or disconnected you must use the following procedure. 1. Remove the RTD sensor from the vehicle. 2. While supporting the sensor lever by hand, twist the link rod to remove it from the ball stud. 3. Remove the link rod from the frame bracket ball stud. Installation Procedure 1. Using the J38185 install to link rod to the ball stud on the sensor lever and the frame bracket. 2. Install the RTD sensor to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Steering Wheel Speed/Position Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Steering Wheel Speed/Position Sensor - W/ RTD Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Steering Wheel Speed/Position Sensor - W/ RTD > Page 10068 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Page 10069 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Removal Procedure 1. Set the front wheels in the straight-ahead position. Set the steering wheel in the LOCKED position. 2. Disable the Supplemental Inflatable Restraint (SIR). 3. Remove the nut and the bolt (1) from the upper intermediate shaft connection and slide the intermediate steering shaft down. 4. Remove the position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. Important: Do not apply force to the sensor and the bearing in a sideways direction. 5. Remove the position sensor and bearing assembly from the steering column jacket by pulling the assembly straight out. 6. Remove the position sensor from the clips in the bearing assembly. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Page 10070 1. Install the position sensor into the bearing assembly. Important: Do not apply force to the sensor and the bearing in a sideways direction. 2. Install the bearing into the steering column jacket. 2.1. Align the notches on the bearing and the column jacket. 2.2. Seat the bearing fulling into the jacket. 3. Connect the position sensor connector. Notice: Refer to Fastener Notice in Service Precautions. 4. Slide the shaft up to install the bolt and the nut (1) to the upper intermediate shaft to steering column connection. Tighten the upper intermediate shaft connection to 47 Nm (35 ft. lbs.). 5. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Control Pressure Sensor/Switch > Component Information > Service and Repair Suspension Control Pressure Sensor/Switch: Service and Repair "For information regarding this component please refer to air dryer suspension control service and repair" Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair Center Link: Service and Repair Relay Rod Replacement Tools Required ^ J24319-B Universal Steering Linkage Puller ^ J29193 Steering Linkage Installer (12 mm) ^ J29194 Steering Linkage Installer (14 mm) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield, if equipped. 3. Remove the steering damper from the relay rod, if equipped. Important: Use the proper tool in order to separate all the tie rod and the ball joints. 4. Remove the tie rod ends (6). 5. Remove the idler arm ball stud nut (10). Do not reuse the nut. 6. Remove the pitman arm nut (8). Do not reuse the nut. 7. Remove the relay rod from the idler arm ball stud using the J24319-B. 8. Remove the relay rod from the pitman arm ball stud using the J24319-B. 9. Remove the relay rod from the vehicle. 10. Inspect the threads on the tie rod ends for damage. 11. Inspect the ball stud threads for damage. 12. Inspect the ball stud seals for excessive damage. 13. Clean the threads on the ball studs. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Page 10083 1. Install the relay rod (9) to the vehicle. 2. Install the relay rod (9) to the pitman arm ball stud (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the relay rod (9) to the idler arm ball stud (1). Ensure the seal is on the stud. 4. Install the J29193 or the J29194. 5. Tighten the steering linkage installer in order to seat the tapers. Tighten the steering linkage installer to 54 Nm (40 ft. lbs.). 6. Remove the J29193 or the J29194. 7. Install the new pitman arm prevailing torque nut. 8. Install the new idler arm prevailing torque nut. Tighten the nuts to 62 Nm (46 ft. lbs.). 9. Install the tie rod ends. 10. Install the steering dampner to the relay rod, if equipped. 11. Install the engine protection shield, if equipped. 12. Lower the vehicle. 13. Check the wheel alignment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Steering Knuckle Replacement Tools Required ^ J43631 Ball Joint Separating Tool Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Disconnect the Real Time Damping (RTD) link rod from the sensor, if equipped. 4. Unload the torsion bars. 5. Remove the wheel hub and bearing assembly. 6. Disconnect the outer tie rod to the steering knuckle. 7. Remove the brake hose bracket retaining bolt from the steering knuckle. 8. Remove the upper control arm retaining nut and separate the upper ball joint from the steering knuckle (2) using the J43631 (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 10087 9. Remove the lower control arm retaining nut. Separate the lower ball joint from the steering knuckle (2) using the J43631(1). 10. Remove the steering knuckle. Installation Procedure 1. Clean all grease and contaminants from the tapered section and the threads of the upper ball joint, the lower ball joint, and the tie rod end. 2. Clean and inspect the taper holes and the mounting surfaces of the steering knuckle. If any of the tapered holes are elongated, out of round, or damaged, replace the steering knuckle. 3. Install the steering knuckle. Notice: Refer to Fastener Notice in Service Precautions. 4. Connect the lower ball joint to the steering knuckle and install the retaining nut. Tighten the lower control arm retaining nut to 100 Nm (74 ft. lbs.). 5. Connect the upper ball joint to the steering knuckle and install the retaining nut. Tighten the upper control arm retaining nut to 50 Nm (37 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 10088 6. Install the brake hose and the bracket retaining bolt to the steering knuckle Tighten the bolt to 9 Nm (80 inch lbs.). 7. Connect the outer tie rod to the steering knuckle. 8. Install the wheel hub and bearing assembly. 9. Connect the RTD link rod to the sensor, if equipped. 10. Install the tire and wheel. 11. Load the torsion bars. 12. Align the vehicle. 13. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications Idler Arm: Specifications Idler Arm to Frame Nut ........................................................................................................................ .................................................... 99 Nm (73 ft. lbs.) Idler Arm to Relay Rod Nut ............................... ...................................................................................................................................... 62 Nm (46 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 10092 Idler Arm: Testing and Inspection Idler Arm Inspection Tools Required ^ J 35999 Spring Scale ^ J 42640 Steering Column Anti-Rotation Pin ^ J 45101 Hub and Wheel Runout Gauge 1. Raise the vehicle on a hoist. Support the vehicle with jackstands. Notice: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: ^ The steering column ^ The intermediate shaft(s) ^ The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil’s centering procedure to re-center SIR Coil. 2. Position the wheels in a straight-ahead position and install the J 42640. 3. Install the dial indicator J 45101 between the idler arm and vehicle frame. Ensure the gauge is at zero before taking a measurement. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 10093 4. Place a J 35999 near the relay rod end of the idler arm. 5. Exert a 110 Nm (25 lb) force upward, and then downward while measuring the total distance the arm moves. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 10094 6. If movement exceeds 2 mm (0.078 in) replace the idler arm. 7. Install the dial indicator at the idler arm. 8. Push the tire inward slowly with one hand to remove any lash. Zero out the dial indicator and pull outward in order to take a reading. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 10095 9. Allow only 1 mm (0.039 in) of movement at the idler arm ball stud. If more than 1 mm exists, replace the idler arm. 10. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 10096 Idler Arm: Service and Repair Idler Arm Replacement Tools Required ^ J24319-B Universal Steering Linkage Puller ^ J29193 Steering Linkage Installer (12 mm) ^ J29194 Steering Linkage installer (14 mm) Removal Procedure Notice: Do not attempt to free the ball stud by using a pickle fork or wedge type tool, because seal or bushing damage could result. Use the proper tool to separate all ball joints. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield, if equipped. 3. Remove the idler arm ball stud nut (10). Do not reuse the idler arm ball stud nut. 4. Remove the idler arm from the relay rod using the J24319-B. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 10097 5. Remove the idler arm frame bolts (3) and the nuts (1). 6. Remove the idler arm (2) from the vehicle. Installation Procedure 1. Position the idler arm (2) on the frame. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the frame bolts (3) and the nuts (1) to the idler arm. Tighten Tighten the frame bolts to 99 Nm (73 ft. lbs.). 3. Install the relay rod (9) to the idler arm ball stud (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 10098 Ensure the seal is on the stud. 4. Use the J29193 in order to seat the tapers. Tighten Tighten the J29193 or the J29194 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 5. Install the new idler arm ball stud prevailing torque nut to the idler arm ball stud. Tighten Tighten the nut to 62 Nm (46 ft. lbs.). 6. Install the engine protection shield, if equipped. 7. Lower the vehicle. 8. Check the wheel alignment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Steering/Suspension - Pitman Arm Shaft Seal Service Kit Pitman Arm: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 10103 Pitman Arm: Specifications Pitman Arm to Relay Rod Nut ............................................................................................................. ...................................................... 62 Nm 46 ft. lbs. Pitman Arm to Steering Gear Nut ........................................................................................................................................................... 250 Nm 184 ft. lbs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 10104 Pitman Arm: Service and Repair Pitman Arm Replacement Tools Required ^ J6632-01 Pitman Arm Puller ^ J29193 Steering Linkage Installer (12 mm) ^ J29194 Steering Linkage Installer (14 mm) ^ J29107-A Universal Pitman Arm Puller ^ J24319-B Universal Steering Linkage Puller Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield, if equipped. 3. Remove the relay rod nut (8) from the pitman arm ball stud (2). Do not reuse the nut. Notice: Do not hammer on the pitman arm, pitman arm shaft or puller. Damage to the pitman arm or steering gear may result. 4. Use the J24319-B in order to remove the relay rod from the pitman arm ball stud. 5. Remove the power steering gear. Mark the pitman arm and the pitman shaft in order to ensure the proper alignment at assembly. 6. Remove the pitman arm nut. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 10105 7. Use the J29107-A or J6632-01 in order to remove the pitman arm from the steering gear pitman shaft. 8. Inspect the ball stud threads for damage. 9. Inspect the ball stud seals for excessive wear. 10. Clean the threads on the ball stud. Installation Procedure 1. Install the pitman arm on the pitman shaft. 2. Align the marks made at the removal on the pitman arm and the pitman arm shaft. Notice: Refer to Fastener Notice in Service Precautions. 3. Install a new pitman arm nut. Tighten the pitman arm nut to 250 Nm (184 ft. lbs.). 4. Install the power steering gear. 5. Install the relay rod (9) to the pitman arm ball stud. 6. Ensure the seal is on the stud. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 10106 7. Install the J29193 or the J29194. Tighten the J29193 or the J29194 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 8. Remove the J29193 or the J29194. 9. Install the new relay rod prevailing torque nut. Tighten the new prevailing torque nut to 62 Nm (46 ft. lbs.). 10. Install the engine protection shield, if equipped. 11. Lower the vehicle. 12. Check the wheel alignment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Power Steering System Bleeding Important: - Use clean, new power steering fluid type only. See: Maintenance - Hoses touching the frame, body or engine may cause system noise. Verify that the hoses do not touch any other part of the vehicle. - Loose connections may not leak, but could allow air into the steering system. Verify that all hose connections are tight. - Power steering fluid level must be maintained throughout bleed procedure. 1. Fill pump reservoir with fluid to minimum system level, FULL COLD level, or middle of hash mark on cap stick fluid level indicator. Important: With hydro-boost only, the oil level will appear falsely high if the hydro-boost accumulator is not fully charged. Do not apply the brake pedal with the engine OFF. This will discharge the hydro-boost accumulator. 2. If equipped with hydro-boost, fully charge the hydro-boost accumulator using the following procedure: 2.1 Start the engine. 2.2 Firmly apply the brake pedal 10-15 times. 2.3 Turn the engine OFF. 3. Raise the vehicle until the front wheels are off the ground. 4. Key on engine OFF, turn the steering wheel from stop to stop 12 times. - Vehicle equipped with hydro-boost systems or longer length power steering hoses may require turns up to 15 to 20 stop to stops. 5. Verify power steering fluid level per operation specification. See: Power Steering Fluid 6. Start the engine. Rotate steering wheel from left to right. Check for sign of cavitation or fluid aeration (pump noise/whining). 7. Verify the fluid level. Repeat the bleed procedure, if necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications Power Steering System GM Power Steering Fluid (GM Part No. 1052884 - 1 pint, 1050017 - 1 quart, or equivalent). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications Power Steering Fluid Cooler: Specifications Power Steering Cooler Mounting Bolts ..................................................................................................................................................... 5 Nm 44 inch lbs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Without Hydroboost Power Steering Fluid Cooler: Service and Repair Without Hydroboost Power Steering Cooler Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Remove the front grille. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 2. Remove the clamp retaining the power steering outlet hose (3) from the power steering gear (4). 3. Remove the clamp retaining the power steering inlet hose from the power steering pump (5). 4. Remove the bolts (2) retaining the power steering cooler from the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the power steering cooler (1) to the vehicle. Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Without Hydroboost > Page 10119 2. Connect the power steering outlet hose (3) to the power steering gear (4). Install the retaining clamp. 3. Connect the power steering inlet hose to the power steering pump. Install the retaining clamp. 4. Bleed the power steering system. 5. Inspect all the hose connections for leaks. 6. Install the front grille. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Without Hydroboost > Page 10120 Power Steering Fluid Cooler: Service and Repair With Hydroboost Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) Removal Procedure 1. Remove the front grille. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 2. Place a drain pan under the vehicle. 3. Siphon the fluid from the reservoir to prevent excess spillage. 4. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear (2). 5. Remove the clamp retaining power steering cooler outlet hose (5) to the power steering pump (1). 6. Remove the bolts (2) retaining the power steering cooler from the radiator support. 7. Remove the power steering cooler from the vehicle. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Without Hydroboost > Page 10121 1. Install the power steering cooler (1) to the radiator support. Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). 2. Install the power steering cooler outlet hose (3) to the power steering pump (2). Install the retaining clamp. 3. Install the power steering inlet hose (5) to the power steering gear (1). Install the retaining clamp. 4. Fill and bleed the power steering system. 5. Inspect all the hose connections for leaks. 6. Install the front grille. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair Power Steering Fluid Reservoir: Service and Repair "For information regarding this component please refer to power steering pump service and repair" Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure Hose Connection (At Gear) ........................................................................................................................................................ 33 Nm (24 ft. lbs.) Pressure Hose Connection (At Pump) ...................................................................................................................................................... 28 Nm (20 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Brake Booster Inlet Hose Replacement Power Steering Line/Hose: Service and Repair Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Install a drain pan under the vehicle. 2. Remove the brake booster inlet hose (1) from the brake booster (2). 3. Remove the brake booster inlet hose from the power steering pump. 4. Remove the brake booster inlet hose from the vehicle. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 1. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster inlet hose (1) to the brake booster (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the brake booster inlet hose to the power steering pump. Tighten the brake booster inlet hose fittings to 27 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Brake Booster Inlet Hose Replacement > Page 10130 Power Steering Line/Hose: Service and Repair Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Install a drain pan under the vehicle. 2. Remove the brake booster outlet hose (1) from the brake booster (2). 3. Remove the clamp retaining the brake booster outlet hose to the power steering pump. 4. Remove the brake booster outlet hose from the vehicle. Installation Procedure Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. 1. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster outlet hose (1) to the brake booster (2). Position the clamp at the end of the hose. 3. Install the brake booster outlet hose to the power steering pump (4). Position the clamp at the end of the hose. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Brake Booster Inlet Hose Replacement > Page 10131 Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Hose Replacement With Hydroboost Power Steering Gear Inlet Hose Replacement (With Hydroboost) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Install a drain pan under the vehicle. 2. Remove the power steering gear inlet hose (1) from the brake booster. 3. Remove the power steering gear inlet hose from the power steering gear. 4. Remove the power steering gear inlet hose from the vehicle. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 1. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (1) to the brake booster (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering gear inlet hose to the power steering gear. Tighten the power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Brake Booster Inlet Hose Replacement > Page 10132 Without Hydroboost Power Steering Gear Inlet Hose Replacement (Without Hydroboost) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Install a drain pan under the vehicle. 4. Remove the power steering gear inlet hose (3) from the power steering pump (1). 5. Remove the power steering gear inlet hose from the power steering gear. 6. Remove the power steering gear inlet hose from the vehicle. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 1. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (3) to the power steering pump (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering gear inlet hose to the power steering gear. Tighten the power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Install the engine protection shield. 6. Lower the vehicle. 7. Bleed the power steering system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Brake Booster Inlet Hose Replacement > Page 10133 Power Steering Line/Hose: Service and Repair Power Steering Gear Outlet Hose Replacement Power Steering Gear Outlet Hose Replacement (Recirculating Ball) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Install a drain pan under the vehicle. 2. Remove the power steering gear outlet hose (3) from the steering gear (2). 3. Remove the clamp retaining the power steering gear outlet hose (3) to the power steering pump (1) Remove the power steering gear outlet hose from the power steering pump. 4. Remove the power steering gear outlet hose from the vehicle. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 1. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear outlet hose (3) to the power steering pump (1). Position the clamp at the end of the hose. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering gear outlet hose to the power steering gear. Tighten the outlet hose fitting to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Specifications Power Steering Pressure Control Valve: Specifications Flow Control Valve Actuator ................................................................................................................ ................................................... 62 Nm (46 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Specifications > Page 10141 Electronic Variable Orifice (EVO) Solenoid Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 01-02-32-007 > Sep > 01 > Accessory Drive Belt - Whining Type Noise Power Steering Pump: Customer Interest Accessory Drive Belt - Whining Type Noise File In Section: 02 - Steering Bulletin No.: 01-02-32-007 Date: September, 2001 TECHNICAL Subject: Accessory Drive Belt Whine (Reposition Power Steering Pump Pulley) Models: 2001-02 Chevrolet and GMC C/K 1500 Series Utility Models (Tahoe, Suburban, Yukon, Yukon XL, Denali, Denali XL) Built at Janesville Assembly Plant (Plant Code J) from December, 2000 through July, 2001 Condition Some customers may comment on a whining-type noise that is audible in the vehicle's passenger compartment. This noise can typically be heard when the vehicle is idling and may vary in pitch as engine RPM is increased. Cause The power steering (PS) pump pulley may be positioned too far inboard on the PS pump. Correction Inspect the PS pump pulley for proper positioning on the PS pump shaft. If it is determined that the pulley is not even/flush with the end of the shaft (+/- 0.25 mm (0.010 in) following the applicable Service Manual procedure and using J 25034-C, reposition the PS pump pulley. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 01-02-32-007 > Sep > 01 > Accessory Drive Belt - Whining Type Noise Power Steering Pump: All Technical Service Bulletins Accessory Drive Belt - Whining Type Noise File In Section: 02 - Steering Bulletin No.: 01-02-32-007 Date: September, 2001 TECHNICAL Subject: Accessory Drive Belt Whine (Reposition Power Steering Pump Pulley) Models: 2001-02 Chevrolet and GMC C/K 1500 Series Utility Models (Tahoe, Suburban, Yukon, Yukon XL, Denali, Denali XL) Built at Janesville Assembly Plant (Plant Code J) from December, 2000 through July, 2001 Condition Some customers may comment on a whining-type noise that is audible in the vehicle's passenger compartment. This noise can typically be heard when the vehicle is idling and may vary in pitch as engine RPM is increased. Cause The power steering (PS) pump pulley may be positioned too far inboard on the PS pump. Correction Inspect the PS pump pulley for proper positioning on the PS pump shaft. If it is determined that the pulley is not even/flush with the end of the shaft (+/- 0.25 mm (0.010 in) following the applicable Service Manual procedure and using J 25034-C, reposition the PS pump pulley. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Power Steering Pump Front Mounting Bolts ............................................................................................................................................ 50 Nm (37 ft. lbs.) Power Steering Pump Rear Mounting Bolt ............................................................................................................................................... 50 Nm (37 ft. lbs.) Flow Control Valve Actuator .............................................................................................. ..................................................................... 62 Nm (46 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 10157 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 10158 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 10159 Power Steering Pump: Testing and Inspection Please see STEERING/TESTING and INSPECTION for information on this component. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley Replacement Power Steering Pump: Service and Repair Power Steering Pulley Replacement Power Steering Pulley Replacement Tools Required ^ J25034-C Power Steering Pump Pulley Remover ^ J25033-C Power Steering Pump Pulley Installer Removal Procedure 1. Remove the upper fan shroud. 2. Remove the drive belt. 3. Remove the power steering pump pulley using the J25034-C. Installation Procedure 1. Place the power steering pump pulley on the end of the power steering pump shaft. 2. Install the power steering pump pulley using J25033-C. 3. Ensure that the power steering pump pulley is flush against the power steering pump shaft, with an allowable variance of 0.25 mm (0.010 inch). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley Replacement > Page 10162 4. Install the drive belt. 5. Install the upper fan shroud. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley Replacement > Page 10163 Power Steering Pump: Service and Repair Power Steering Pump Flow Control Valve Actuator Replacement - On Vehicle Power Steering Pump Flow Control Valve Actuator Replacement - On Vehicle Disassembly Procedure 1. Remove the electrical connector from the variable assist steering actuator (1). 2. Remove pump assembly from the vehicle, if the variable assist steering actuator (1) is not accessible. 3. Remove the retaining ring (2) from the variable assist steering actuator (1). Important: Note the orientation of the variable assist steering actuator discharge fitting. 4. Remove the variable assist steering actuator (1). 5. Remove the O-ring seal from the variable assist steering actuator. Assembly Procedure Important: Note the orientation of the variable assist steering actuator discharge fitting. 1. Lubricate and install the new O-ring seal with power steering fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the variable assist steering actuator (1) to the pump assembly. Tighten the actuator to 62 Nm (46 ft. lbs.). 3. Install the negative battery cable. Important: If a new variable assist steering actuator (1) is being installed, position the electrical connector before installing the retaining ring (2). 4. Install the electrical connector to the variable assist steering actuator (1). 5. Install the retaining ring (2) to the variable assist steering actuator (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley Replacement > Page 10164 Power Steering Pump: Service and Repair Power Steering Pump Flow Control Valve Replacement - Off Vehicle (Regular) Power Steering Pump Flow Control Valve Replacement - Off Vehicle (Regular) Disassembly Procedure 1. Drain the oil from the reservoir (1). 2. Remove the control valve assembly (3) from the pump housing (1). Make sure the flow control spring (4) does not fall out of the pump housing (1). 3. Remove the rectangular section seal (2) from the control valve assembly (3). Assembly Procedure 1. Install the flow control spring (4) if removed from the pump housing (1). 2. Lubricate the new rectangular section seal (2) with power steering fluid. 3. Install the rectangular section seal (2) onto the control valve assembly (3). 4. Install the control valve assembly (3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley Replacement > Page 10165 Power Steering Pump: Service and Repair Power Steering Pump Replacement Power Steering Pump Replacement Removal Procedure 1. Remove the power steering pulley. 2. Place a drain pan under the pump. 3. Remove the hose guide bracket from the front of the pump. 4. For vehicles with variable effort steering, disconnect the electrical connector. 5. Remove the hoses from the pump. 6. Remove the lower intermediate shaft from the steering gear. 7. Remove the bolt retaining the rear bracket to the engine. 8. Remove the bolts from the front of the pump. 9. Remove the pump from the vehicle. 10. Remove the bracket (3) from the rear of the pump (1). Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley Replacement > Page 10166 1. Install the bracket (3) to the rear of the pump (1). Tighten the rear bracket retaining nuts to 50 Nm (37 ft. lbs.). 2. Install the pump. 3. Install the hose guide bracket bolt to the pump. 4. Install the bolt retaining the rear bracket to the engine. 5. Install the bolts to the front of the pump. Tighten the bolts to 50 Nm (37 ft. lbs.). 6. For vehicles with variable effort steering connect the electrical connector. 7. Install the hoses to the pump. Tighten the nut to 28 Nm (20 ft. lbs.). 8. Install the intermediate shaft. 9. Install the power steering pulley. 10. Fill and bleed the power steering system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley Replacement > Page 10167 Power Steering Pump: Service and Repair Power Steering Reservoir Replacement - Off Vehicle Power Steering Reservoir Replacement - Off Vehicle Disassembly Procedure 1. Drain the power steering fluid from the power steering pump. 2. Remove the pump mounting studs (2). 3. Remove the connector and fitting assembly (5). To remove the variable assist steering actuator (3) and retaining ring (4); refer to Power Steering Pump Flow Control Valve Actuator Replacement - On Vehicle. 4. Remove the O-ring seal (6) from the connector and fitting assembly (4). 5. If replacement is required, remove the control valve assembly and the flow control spring from the pump housing assembly. 6. Remove the reservoir assembly (1) from the pump housing assembly (2). 7. Remove the O-ring seals (1) (4). 8. Remove the magnet (3). 9. Clean the magnet (3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley Replacement > Page 10168 10. Inspect the Welch plug in the power steering pump housing (2). Do not remove. If the Welch plug is deformed or dislodged, replace the power steering pump housing (2). Assembly Procedure Important: Use new O-ring seals when assembling the power steering pump assembly. 1. Lubricate the O-ring seals (1) (4) with power steering fluid. 2. To install the control valve assembly and flow control spring to the pump housing assembly (2); refer to Power Steering Pump Flow Control Valve Replacement - Off Vehicle (Regular). 3. Install the O-ring seals (1) (4) to the pump housing assembly (2). 4. Install the magnet (3) to the pump housing assembly (2). 5. Connect the reservoir assembly (1) to the pump housing assembly (2). 6. Install the O-ring seal. 7. Install the connector and fitting assembly (5). To install the variable assist steering actuator (3) and retaining ring (4); refer to Power Steering Pump Flow Control Valve Actuator Replacement - On Vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley Replacement > Page 10169 Notice: Refer to Fastener Notice in Service Precautions. 8. Install the pump mounting studs (2) to the pump housing (1). Tighten the pump mounting studs (2) to 58 Nm (43 ft. lbs.). Tighten the connector and fitting assembly (5) to 75 Nm (55 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Steering Wheel Speed/Position Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Steering Wheel Speed/Position Sensor - W/ RTD Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Steering Wheel Speed/Position Sensor - W/ RTD > Page 10176 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Page 10177 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Removal Procedure 1. Set the front wheels in the straight-ahead position. Set the steering wheel in the LOCKED position. 2. Disable the Supplemental Inflatable Restraint (SIR). 3. Remove the nut and the bolt (1) from the upper intermediate shaft connection and slide the intermediate steering shaft down. 4. Remove the position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. Important: Do not apply force to the sensor and the bearing in a sideways direction. 5. Remove the position sensor and bearing assembly from the steering column jacket by pulling the assembly straight out. 6. Remove the position sensor from the clips in the bearing assembly. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams > Page 10178 1. Install the position sensor into the bearing assembly. Important: Do not apply force to the sensor and the bearing in a sideways direction. 2. Install the bearing into the steering column jacket. 2.1. Align the notches on the bearing and the column jacket. 2.2. Seat the bearing fulling into the jacket. 3. Connect the position sensor connector. Notice: Refer to Fastener Notice in Service Precautions. 4. Slide the shaft up to install the bolt and the nut (1) to the upper intermediate shaft to steering column connection. Tighten the upper intermediate shaft connection to 47 Nm (35 ft. lbs.). 5. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures Steering Column Position Sensor: Technical Service Bulletins Steering - Revised Service Procedures Bulletin No.: 03-02-36-002 Date: July 30, 2003 SERVICE MANUAL UPDATE Subject: Revised Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Procedure and Steering Wheel Position Sensor Centering Procedure Models: 1998-2003 Buick LeSabre, Park Avenue 1998-2003 Cadillac DeVille, Seville 2003 Cadillac CTS 1998-2003 Chevrolet Corvette 1998 Oldsmobile Achieva 1998-2002 Oldsmobile Intrigue 1998-2003 Oldsmobile Aurora 1999-2003 Oldsmobile Alero 1998-2003 Pontiac Bonneville, Grand Am 1998-2000 Chevrolet C/K Pickup Models 1998-2003 Chevrolet Suburban, Tahoe 1999-2003 Chevrolet Silverado 2002-2003 Chevrolet Avalanche 1998-1999 GMC Suburban 1998-2000 GMC C/K Pickup Models 1998-2003 GMC Yukon 1999-2003 GMC Sierra 2000-2003 GMC Yukon Denali, Yukon XL 2003 GMC Sierra Denali This bulletin is being issued to revise the Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement procedure in the Variable Effort Steering (1998-2001 model years) or Steering Wheel and Column (2002-2003 model years) and add the Steering Wheel Position Sensor Centering procedure in the Steering Wheel and Column sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Removal Procedure Caution: Refer to SIR Caution in Cautions and Notices. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. 2. Remove the steering column from the vehicle. Refer to Steering Column Replacement. 3. Remove the following from the steering shaft: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10183 3.1. steering shaft seal (7) 3.2. sensor retainer (6) 3.3. steering wheel position sensor (5), refer to Steering Wheel Position Sensor Centering. 3.4. 2 lower spring retainers (4) 3.5. lower bearing spring (3) 3.6. lower bearing seat (2) 3.7. adapter and bearing assembly (1) Installation Procedure 1. Install the following onto the steering shaft: 1.1. adapter and bearing assembly (1) 1.2. lower bearing seat (2) 1.3. lower bearing spring (3) 1.4. 2 lower spring retainers (4) 1.5. steering wheel position sensor (5) refer to Steering Wheel Position Sensor Centering. 1.6. sensor retainer (6) 1.7. steering shaft seal (7) 1.8. Enable the SIR system. Refer to in SIR. 2. Install the steering column to the vehicle. Refer to Steering Column Replacement. 3. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations below BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10184 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin (note location of the pin hole) ^ A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10185 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation section. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10186 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation section. 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation section. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10187 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin (note location of the pin hole) ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly. ^ A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10188 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats(1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10189 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10190 Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10191 Steering Column Position Sensor: Service and Repair This article has been updated with TSB# 03-02-36-002 REVISED STEERING WHEEL POSITION SENSOR OR STEERING SHAFT LOWER BEARING REPLACEMENT PROCEDURE AND STEERING WHEEL POSITION SENSOR CENTERING PROCEDURE STEERING WHEEL POSITION SENSOR OR STEERING SHAFT LOWER BEARING REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Cautions and Notices. 1. Disable the SIR system. 2. Remove the steering column from the vehicle. 3. Remove the following from the steering shaft: A. steering shaft seal (7) B. sensor retainer (6) C. steering wheel position sensor (5), refer to Steering Wheel Position Sensor Centering. D. two lower spring retainers (4) E. lower bearing spring (3) F. lower bearing seat (2) G. adapter and bearing assembly (1) INSTALLATION PROCEDURE 1. Install the following onto the steering shaft: A. adapter and bearing assembly (1) B. lower bearing seat (2) C. lower bearing spring (3) D. 2 lower spring retainers (4) E. steering wheel position sensor (5) refer to Steering Wheel Position Sensor Centering. F. sensor retainer (6) G. steering shaft seal (7) H. Enable the SIR system. 2. Install the steering column to the vehicle. 3. Enable the SIR system. STEERING WHEEL POSITION SENSOR CENTERING REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10192 IMPORTANT: Identify the type of steering wheel position sensor from the illustrations below BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. IMPORTANT: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin (note location of the pin hole) ^ A flush rotor flange cuff (4) IMPORTANT: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation section. 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10193 ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation section. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation section. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation section. 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin (note location of the pin hole) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10194 ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation section. INSTALLATION PROCEDURE IMPORTANT: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin (note location of the pin hole) ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly. ^ A view of the inside of the connector IMPORTANT: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT: If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10195 ^ An alignment tab (2) for installing into the adapter and bearing assembly. IMPORTANT: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT: If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. IMPORTANT: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT:If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. IMPORTANT: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT:If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10196 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. IMPORTANT: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT: If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations Steering Wheel Speed/Position Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Diagrams > Steering Wheel Speed/Position Sensor - W/ RTD Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Diagrams > Steering Wheel Speed/Position Sensor - W/ RTD > Page 10202 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Diagrams > Page 10203 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Removal Procedure 1. Set the front wheels in the straight-ahead position. Set the steering wheel in the LOCKED position. 2. Disable the Supplemental Inflatable Restraint (SIR). 3. Remove the nut and the bolt (1) from the upper intermediate shaft connection and slide the intermediate steering shaft down. 4. Remove the position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. Important: Do not apply force to the sensor and the bearing in a sideways direction. 5. Remove the position sensor and bearing assembly from the steering column jacket by pulling the assembly straight out. 6. Remove the position sensor from the clips in the bearing assembly. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Diagrams > Page 10204 1. Install the position sensor into the bearing assembly. Important: Do not apply force to the sensor and the bearing in a sideways direction. 2. Install the bearing into the steering column jacket. 2.1. Align the notches on the bearing and the column jacket. 2.2. Seat the bearing fulling into the jacket. 3. Connect the position sensor connector. Notice: Refer to Fastener Notice in Service Precautions. 4. Slide the shaft up to install the bolt and the nut (1) to the upper intermediate shaft to steering column connection. Tighten the upper intermediate shaft connection to 47 Nm (35 ft. lbs.). 5. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the fuse block. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Disconnect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 7. Access the IP module yellow 2-way connector (1) located behind the IP module (2) by removing the upper IP trim panel. Refer to Trim Pad Replacement - IP Upper in Instrument Panel, Gauges and Warning Indicators. 8. Remove the CPA from the IP module yellow 2-way connector (1) located behind the IP module (2). 9. Disconnect the IP module yellow 2-way connector (1) located behind the IP module (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 10210 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the IP module yellow 2-way connector (1) located behind the main IP support. 3. Install the CPA to the IP module yellow 2-way connector (1) located behind the main IP support. 4. Connect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 5. Install the CPA (1) to the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Install the AIR BAG Fuse to the fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - SIR if the AIR BAG indicator does not operate as described. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 00-02-35-003N > Mar > 08 > Steering Underhood Clunk Heard/Felt in Steering Wheel Steering Column Bearing: Customer Interest Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 00-02-35-003N > Mar > 08 > Steering Underhood Clunk Heard/Felt in Steering Wheel > Page 10219 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 00-02-35-003N > Mar > 08 > Steering Underhood Clunk Heard/Felt in Steering Wheel > Page 10220 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 00-02-35-003N > Mar > 08 > Steering Underhood Clunk Heard/Felt in Steering Wheel > Page 10221 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Column Bearing: All Technical Service Bulletins Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 10227 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 10228 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 10229 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures Steering Column Bearing: All Technical Service Bulletins Steering - Revised Service Procedures Bulletin No.: 03-02-36-002 Date: July 30, 2003 SERVICE MANUAL UPDATE Subject: Revised Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Procedure and Steering Wheel Position Sensor Centering Procedure Models: 1998-2003 Buick LeSabre, Park Avenue 1998-2003 Cadillac DeVille, Seville 2003 Cadillac CTS 1998-2003 Chevrolet Corvette 1998 Oldsmobile Achieva 1998-2002 Oldsmobile Intrigue 1998-2003 Oldsmobile Aurora 1999-2003 Oldsmobile Alero 1998-2003 Pontiac Bonneville, Grand Am 1998-2000 Chevrolet C/K Pickup Models 1998-2003 Chevrolet Suburban, Tahoe 1999-2003 Chevrolet Silverado 2002-2003 Chevrolet Avalanche 1998-1999 GMC Suburban 1998-2000 GMC C/K Pickup Models 1998-2003 GMC Yukon 1999-2003 GMC Sierra 2000-2003 GMC Yukon Denali, Yukon XL 2003 GMC Sierra Denali This bulletin is being issued to revise the Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement procedure in the Variable Effort Steering (1998-2001 model years) or Steering Wheel and Column (2002-2003 model years) and add the Steering Wheel Position Sensor Centering procedure in the Steering Wheel and Column sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Removal Procedure Caution: Refer to SIR Caution in Cautions and Notices. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. 2. Remove the steering column from the vehicle. Refer to Steering Column Replacement. 3. Remove the following from the steering shaft: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10234 3.1. steering shaft seal (7) 3.2. sensor retainer (6) 3.3. steering wheel position sensor (5), refer to Steering Wheel Position Sensor Centering. 3.4. 2 lower spring retainers (4) 3.5. lower bearing spring (3) 3.6. lower bearing seat (2) 3.7. adapter and bearing assembly (1) Installation Procedure 1. Install the following onto the steering shaft: 1.1. adapter and bearing assembly (1) 1.2. lower bearing seat (2) 1.3. lower bearing spring (3) 1.4. 2 lower spring retainers (4) 1.5. steering wheel position sensor (5) refer to Steering Wheel Position Sensor Centering. 1.6. sensor retainer (6) 1.7. steering shaft seal (7) 1.8. Enable the SIR system. Refer to in SIR. 2. Install the steering column to the vehicle. Refer to Steering Column Replacement. 3. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations below BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10235 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin (note location of the pin hole) ^ A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10236 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation section. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10237 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation section. 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation section. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10238 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin (note location of the pin hole) ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly. ^ A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10239 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats(1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10240 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10241 Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures Steering Column Bearing: All Technical Service Bulletins Steering - Revised Service Procedures Bulletin No.: 03-02-36-002 Date: July 30, 2003 SERVICE MANUAL UPDATE Subject: Revised Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Procedure and Steering Wheel Position Sensor Centering Procedure Models: 1998-2003 Buick LeSabre, Park Avenue 1998-2003 Cadillac DeVille, Seville 2003 Cadillac CTS 1998-2003 Chevrolet Corvette 1998 Oldsmobile Achieva 1998-2002 Oldsmobile Intrigue 1998-2003 Oldsmobile Aurora 1999-2003 Oldsmobile Alero 1998-2003 Pontiac Bonneville, Grand Am 1998-2000 Chevrolet C/K Pickup Models 1998-2003 Chevrolet Suburban, Tahoe 1999-2003 Chevrolet Silverado 2002-2003 Chevrolet Avalanche 1998-1999 GMC Suburban 1998-2000 GMC C/K Pickup Models 1998-2003 GMC Yukon 1999-2003 GMC Sierra 2000-2003 GMC Yukon Denali, Yukon XL 2003 GMC Sierra Denali This bulletin is being issued to revise the Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement procedure in the Variable Effort Steering (1998-2001 model years) or Steering Wheel and Column (2002-2003 model years) and add the Steering Wheel Position Sensor Centering procedure in the Steering Wheel and Column sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Removal Procedure Caution: Refer to SIR Caution in Cautions and Notices. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. 2. Remove the steering column from the vehicle. Refer to Steering Column Replacement. 3. Remove the following from the steering shaft: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10247 3.1. steering shaft seal (7) 3.2. sensor retainer (6) 3.3. steering wheel position sensor (5), refer to Steering Wheel Position Sensor Centering. 3.4. 2 lower spring retainers (4) 3.5. lower bearing spring (3) 3.6. lower bearing seat (2) 3.7. adapter and bearing assembly (1) Installation Procedure 1. Install the following onto the steering shaft: 1.1. adapter and bearing assembly (1) 1.2. lower bearing seat (2) 1.3. lower bearing spring (3) 1.4. 2 lower spring retainers (4) 1.5. steering wheel position sensor (5) refer to Steering Wheel Position Sensor Centering. 1.6. sensor retainer (6) 1.7. steering shaft seal (7) 1.8. Enable the SIR system. Refer to in SIR. 2. Install the steering column to the vehicle. Refer to Steering Column Replacement. 3. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations below BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10248 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin (note location of the pin hole) ^ A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10249 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation section. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10250 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation section. 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation section. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10251 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin (note location of the pin hole) ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly. ^ A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10252 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats(1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10253 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Bearing: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10254 Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures Steering Column Position Sensor: Technical Service Bulletins Steering - Revised Service Procedures Bulletin No.: 03-02-36-002 Date: July 30, 2003 SERVICE MANUAL UPDATE Subject: Revised Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Procedure and Steering Wheel Position Sensor Centering Procedure Models: 1998-2003 Buick LeSabre, Park Avenue 1998-2003 Cadillac DeVille, Seville 2003 Cadillac CTS 1998-2003 Chevrolet Corvette 1998 Oldsmobile Achieva 1998-2002 Oldsmobile Intrigue 1998-2003 Oldsmobile Aurora 1999-2003 Oldsmobile Alero 1998-2003 Pontiac Bonneville, Grand Am 1998-2000 Chevrolet C/K Pickup Models 1998-2003 Chevrolet Suburban, Tahoe 1999-2003 Chevrolet Silverado 2002-2003 Chevrolet Avalanche 1998-1999 GMC Suburban 1998-2000 GMC C/K Pickup Models 1998-2003 GMC Yukon 1999-2003 GMC Sierra 2000-2003 GMC Yukon Denali, Yukon XL 2003 GMC Sierra Denali This bulletin is being issued to revise the Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement procedure in the Variable Effort Steering (1998-2001 model years) or Steering Wheel and Column (2002-2003 model years) and add the Steering Wheel Position Sensor Centering procedure in the Steering Wheel and Column sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Removal Procedure Caution: Refer to SIR Caution in Cautions and Notices. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. 2. Remove the steering column from the vehicle. Refer to Steering Column Replacement. 3. Remove the following from the steering shaft: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10259 3.1. steering shaft seal (7) 3.2. sensor retainer (6) 3.3. steering wheel position sensor (5), refer to Steering Wheel Position Sensor Centering. 3.4. 2 lower spring retainers (4) 3.5. lower bearing spring (3) 3.6. lower bearing seat (2) 3.7. adapter and bearing assembly (1) Installation Procedure 1. Install the following onto the steering shaft: 1.1. adapter and bearing assembly (1) 1.2. lower bearing seat (2) 1.3. lower bearing spring (3) 1.4. 2 lower spring retainers (4) 1.5. steering wheel position sensor (5) refer to Steering Wheel Position Sensor Centering. 1.6. sensor retainer (6) 1.7. steering shaft seal (7) 1.8. Enable the SIR system. Refer to in SIR. 2. Install the steering column to the vehicle. Refer to Steering Column Replacement. 3. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations below BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10260 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin (note location of the pin hole) ^ A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10261 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation section. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10262 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation section. 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation section. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10263 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin (note location of the pin hole) ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly. ^ A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10264 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats(1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10265 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Steering - Revised Service Procedures > Page 10266 Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10267 Steering Column Position Sensor: Service and Repair This article has been updated with TSB# 03-02-36-002 REVISED STEERING WHEEL POSITION SENSOR OR STEERING SHAFT LOWER BEARING REPLACEMENT PROCEDURE AND STEERING WHEEL POSITION SENSOR CENTERING PROCEDURE STEERING WHEEL POSITION SENSOR OR STEERING SHAFT LOWER BEARING REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Cautions and Notices. 1. Disable the SIR system. 2. Remove the steering column from the vehicle. 3. Remove the following from the steering shaft: A. steering shaft seal (7) B. sensor retainer (6) C. steering wheel position sensor (5), refer to Steering Wheel Position Sensor Centering. D. two lower spring retainers (4) E. lower bearing spring (3) F. lower bearing seat (2) G. adapter and bearing assembly (1) INSTALLATION PROCEDURE 1. Install the following onto the steering shaft: A. adapter and bearing assembly (1) B. lower bearing seat (2) C. lower bearing spring (3) D. 2 lower spring retainers (4) E. steering wheel position sensor (5) refer to Steering Wheel Position Sensor Centering. F. sensor retainer (6) G. steering shaft seal (7) H. Enable the SIR system. 2. Install the steering column to the vehicle. 3. Enable the SIR system. STEERING WHEEL POSITION SENSOR CENTERING REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10268 IMPORTANT: Identify the type of steering wheel position sensor from the illustrations below BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. IMPORTANT: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin (note location of the pin hole) ^ A flush rotor flange cuff (4) IMPORTANT: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation section. 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10269 ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation section. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation section. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation section. 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin (note location of the pin hole) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10270 ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation section. INSTALLATION PROCEDURE IMPORTANT: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin (note location of the pin hole) ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly. ^ A view of the inside of the connector IMPORTANT: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT: If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10271 ^ An alignment tab (2) for installing into the adapter and bearing assembly. IMPORTANT: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT: If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. IMPORTANT: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT:If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. IMPORTANT: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT:If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Technical Service Bulletins > Page 10272 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. IMPORTANT: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. IMPORTANT: If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Specifications Steering Damper: Specifications Steering Dampner to Frame Bracket Nut .................................................................................................................................................. 40 Nm (30 ft. lbs.) Steering Dampner to Relay Rod Nut ........................................................................................................................................................ 62 Nm (46 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Specifications > Page 10276 Steering Damper: Service and Repair Steering Damper Replacement Tools Required ^ J24319-B Universal Steering Linkage Puller ^ J29193 Steering Linkage Installer-12 mm Removal Procedure 1. Raise the vehicle. Support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the engine protection shield, if equipped. Important: Do not reuse the nut. 3. Remove the steering damper (2) ball stud nut (1). 4. Remove the steering damper ball stud from the relay rod using the J24319-B. Important: Do not reuse the nut. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Specifications > Page 10277 5. Remove the steering damper mounting bolt (5) and the nut (6). 6. Remove the steering damper (4) from the vehicle. 7. Inspect the following parts: ^ The steering damper for leaks and damage ^ The mounting bolts and the nuts for damage or corrosion Installation Procedure 1. Install the steering damper (4). 2. Install the mounting bolt (5) and a new prevailing torque nut (6). 3. Install the steering damper ball stud (2) to the relay rod (3). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the J29193. 5. Tighten the steering linkage installer in order to seat the ball stud in the relay rod. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Specifications > Page 10278 Tighten the installer to 54 Nm (40 ft. lbs.). 6. Remove the J29193. 7. Install the prevailing torque nuts. Tighten the mounting nut to 40 Nm (30 ft. lbs.). Tighten the ball stud nut to 62 Nm (46 ft. lbs.). 8. Install the engine protection shield, if equipped. 9. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Technical Service Bulletins > Steering/Suspension - Pitman Arm Shaft Seal Service Kit Steering Gear Seal: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions Steering Mounted Controls Transmitter: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10289 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10290 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10291 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10292 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10293 Steering Mounted Controls Transmitter: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10294 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10295 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10296 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10297 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10298 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10299 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10300 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10301 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10302 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10303 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10304 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10305 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10306 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10307 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10308 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10309 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10310 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10311 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10312 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10313 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10314 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10315 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10316 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10317 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10318 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10319 Steering Wheel Controls Schematics: Steering Wheel Controls Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 10320 Steering Mounted Controls Transmitter: Description and Operation STEERING WHEEL CONTROLS (SWC) PROG Press this button to play a station you have programmed on the radio preset buttons on the selected band. If a cassette tape is playing, press this button to play the other side of the tape. If a compact disc is playing in the console-mounted CD changer, press this button to go to the next available CD. SEEK Press the up arrow to tune to the next radio station and the down arrow to tune to the previous radio station. If a cassette tape or compact disc is playing, the player will advance forward with the up arrow to the next track or backward with the down arrow to the previous track. MUTE Press this button to silence the system. Press it again to turn on the sound. VOL Press the up or down arrow to increase or decrease volume. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 10321 Steering Mounted Controls Transmitter: Testing and Inspection Steps 1-7 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 10322 Steps 8-10 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Shaft: Customer Interest Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 10331 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 10332 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 10333 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Shaft: All Technical Service Bulletins Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 10339 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 10340 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 10341 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures Steering Shaft: All Technical Service Bulletins Steering - Revised Service Procedures Bulletin No.: 03-02-36-002 Date: July 30, 2003 SERVICE MANUAL UPDATE Subject: Revised Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Procedure and Steering Wheel Position Sensor Centering Procedure Models: 1998-2003 Buick LeSabre, Park Avenue 1998-2003 Cadillac DeVille, Seville 2003 Cadillac CTS 1998-2003 Chevrolet Corvette 1998 Oldsmobile Achieva 1998-2002 Oldsmobile Intrigue 1998-2003 Oldsmobile Aurora 1999-2003 Oldsmobile Alero 1998-2003 Pontiac Bonneville, Grand Am 1998-2000 Chevrolet C/K Pickup Models 1998-2003 Chevrolet Suburban, Tahoe 1999-2003 Chevrolet Silverado 2002-2003 Chevrolet Avalanche 1998-1999 GMC Suburban 1998-2000 GMC C/K Pickup Models 1998-2003 GMC Yukon 1999-2003 GMC Sierra 2000-2003 GMC Yukon Denali, Yukon XL 2003 GMC Sierra Denali This bulletin is being issued to revise the Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement procedure in the Variable Effort Steering (1998-2001 model years) or Steering Wheel and Column (2002-2003 model years) and add the Steering Wheel Position Sensor Centering procedure in the Steering Wheel and Column sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Removal Procedure Caution: Refer to SIR Caution in Cautions and Notices. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. 2. Remove the steering column from the vehicle. Refer to Steering Column Replacement. 3. Remove the following from the steering shaft: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10346 3.1. steering shaft seal (7) 3.2. sensor retainer (6) 3.3. steering wheel position sensor (5), refer to Steering Wheel Position Sensor Centering. 3.4. 2 lower spring retainers (4) 3.5. lower bearing spring (3) 3.6. lower bearing seat (2) 3.7. adapter and bearing assembly (1) Installation Procedure 1. Install the following onto the steering shaft: 1.1. adapter and bearing assembly (1) 1.2. lower bearing seat (2) 1.3. lower bearing spring (3) 1.4. 2 lower spring retainers (4) 1.5. steering wheel position sensor (5) refer to Steering Wheel Position Sensor Centering. 1.6. sensor retainer (6) 1.7. steering shaft seal (7) 1.8. Enable the SIR system. Refer to in SIR. 2. Install the steering column to the vehicle. Refer to Steering Column Replacement. 3. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations below BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10347 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin (note location of the pin hole) ^ A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10348 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation section. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10349 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation section. 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation section. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10350 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin (note location of the pin hole) ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly. ^ A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10351 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats(1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10352 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10353 Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures Steering Shaft: All Technical Service Bulletins Steering - Revised Service Procedures Bulletin No.: 03-02-36-002 Date: July 30, 2003 SERVICE MANUAL UPDATE Subject: Revised Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Procedure and Steering Wheel Position Sensor Centering Procedure Models: 1998-2003 Buick LeSabre, Park Avenue 1998-2003 Cadillac DeVille, Seville 2003 Cadillac CTS 1998-2003 Chevrolet Corvette 1998 Oldsmobile Achieva 1998-2002 Oldsmobile Intrigue 1998-2003 Oldsmobile Aurora 1999-2003 Oldsmobile Alero 1998-2003 Pontiac Bonneville, Grand Am 1998-2000 Chevrolet C/K Pickup Models 1998-2003 Chevrolet Suburban, Tahoe 1999-2003 Chevrolet Silverado 2002-2003 Chevrolet Avalanche 1998-1999 GMC Suburban 1998-2000 GMC C/K Pickup Models 1998-2003 GMC Yukon 1999-2003 GMC Sierra 2000-2003 GMC Yukon Denali, Yukon XL 2003 GMC Sierra Denali This bulletin is being issued to revise the Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement procedure in the Variable Effort Steering (1998-2001 model years) or Steering Wheel and Column (2002-2003 model years) and add the Steering Wheel Position Sensor Centering procedure in the Steering Wheel and Column sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Removal Procedure Caution: Refer to SIR Caution in Cautions and Notices. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. 2. Remove the steering column from the vehicle. Refer to Steering Column Replacement. 3. Remove the following from the steering shaft: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10359 3.1. steering shaft seal (7) 3.2. sensor retainer (6) 3.3. steering wheel position sensor (5), refer to Steering Wheel Position Sensor Centering. 3.4. 2 lower spring retainers (4) 3.5. lower bearing spring (3) 3.6. lower bearing seat (2) 3.7. adapter and bearing assembly (1) Installation Procedure 1. Install the following onto the steering shaft: 1.1. adapter and bearing assembly (1) 1.2. lower bearing seat (2) 1.3. lower bearing spring (3) 1.4. 2 lower spring retainers (4) 1.5. steering wheel position sensor (5) refer to Steering Wheel Position Sensor Centering. 1.6. sensor retainer (6) 1.7. steering shaft seal (7) 1.8. Enable the SIR system. Refer to in SIR. 2. Install the steering column to the vehicle. Refer to Steering Column Replacement. 3. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations below BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10360 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin (note location of the pin hole) ^ A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10361 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation section. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10362 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation section. 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation section. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10363 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin (note location of the pin hole) ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly. ^ A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10364 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats(1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10365 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 10366 Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Page 10367 Steering Shaft: Specifications Intermediate Shaft Coupler Bolt ............................................................................................................................................................ 50 Nm (37 inch lbs.) Intermediate Shaft Pinch Bolt ............................................................................. ...................................................................................... 47 Nm (35 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Page 10368 Steering Shaft: Service and Repair "For information regarding this component please refer to steering column service and repair" Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Steering Wheel - Removal Procedure Revision Steering Wheel: Technical Service Bulletins Steering Wheel - Removal Procedure Revision Bulletin No.: 03-02-35-006 Date: December 02, 2003 SERVICE MANUAL UPDATE Subject: Revised Steering Wheel Replacement Procedure Models: 2002 Cadillac Escalade, Escalade EXT 2001-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalanche 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet Express, SSR 2001-2002 GMC Sierra, Yukon, Yukon Denali, Yukon XL 2002-2003 GMC Envoy, Envoy XL 2003 GMC Savana 2002-2003 Oldsmobile Bravada 2003 HUMMER H2 2003 Isuzu Ascender This bulletin is being issued to revise the Steering Wheel Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Steering Wheel - Removal Procedure Revision > Page 10373 The steering wheel puller legs currently recommended in the Service Manual for use with steering wheel puller J 1859-A are incorrect and will not work on these vehicles. The correct steering wheel puller legs that should be used with steering wheel puller J 1859-A are J 36541-A or J 42578. The Steering Wheel Replacement procedure has been updated with the correct steering wheel puller tool usage. Refer to the table for SI Document ID numbers. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Technical Service Bulletins > Steering - New Inner Tie Rod Service Parts Tie Rod: Technical Service Bulletins Steering - New Inner Tie Rod Service Parts Bulletin No.: 03-02-34-001A Date: October 06, 2003 INFORMATION Subject: Inner Tie Rod Released for Service Models: 2002-2004 Cadillac Escalade, Escalade EXT 1500 Series 2003 Cadillac Escalade ESV 1500 Series 1999-2004 Chevrolet Silverado 4WD 1500 Series 2000-2004 Chevrolet Suburban, Tahoe 1500 Series Models 2002-2004 Chevrolet Avalanche 1500 Series Models 1999-2004 GMC Sierra 4WD 1500 Series Models 2000-2004 GMC Yukon, Yukon XL, Yukon Denali 1500 Series Models 2003-2004 HUMMER H2 Supercede: This bulletin is being revised to correct the model information. Please discard Corporate Bulletin Number 03-02-34-001 (Section 02 - Steering). This bulletin is being issued to inform dealers that the inner tie rod can now be serviced separately on vehicles that use steering linkage relay rod kit, P/N 12471375 or P/N 89040375. In cases where only the inner tie rod is required, use P/N 26059210 and follow the Tie Rod Replacement - Inner procedure in the Steering Linkage (Non-Rack and Pinion) subsection. Parts are currently available from GMSPO. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Technical Service Bulletins > Page 10378 Tie Rod: Specifications Tie Rod Jam Nut .................................................................................................................................. ..................................................... 68 Nm (50 ft. lbs.) Tie Rod to Steering Knuckle Nut ............................................................................................................................................................. 45 Nm (33 ft. lbs.) Outer Tie Rod Jam Nut .......................................................................................... ................................................................................... 68 Nm (50 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Technical Service Bulletins > Page 10379 Tie Rod: Service and Repair Tie Rod Replacement Tools Required ^ J24319-B Universal Steering Linkage Puller ^ J29193 Steering Linkage Installer-12 mm Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Important: Use the J24319-B in order to separate all the tie rods and ball joints. 2. Remove the nut (2) from the outer tie rod ball stud (3). 3. Use the J24319-B in order to remove the outer tie rod ball stud from the steering knuckle. Important: Do not reuse the nut. 4. Remove the tie rod end from the shaft by loosening the jam nut. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Technical Service Bulletins > Page 10380 5. Remove the outer tie rod end from the relay rod. 6. Inspect the shaft (6) for bent or damaged threads. 7. Clean the tapered surface of the steering knuckle (1). Installation Procedure 1. Lubricate the tie rod threads with chassis lubricant. 2. Install the tie rod end (4) to the shaft (6). 3. Install the outer tie rod ball stud (3) to the steering knuckle (1). Notice: Refer to Fastener Notice in Service Precautions. 4. Use the J29193 in order to install the outer tie rod ball stud. Tighten the J29193 to 54 Nm (40 ft. lbs.) in order to seat the tapers. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Technical Service Bulletins > Page 10381 5. Install the new prevailing torque nut (2) to the outer rod ball stud (3). Tighten the nut to 45 Nm (33 ft. lbs.). 6. Adjust the front toe. 7. Tighten the jam nut (5). Tighten the nut to 68 Nm (50 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Lower Ball Joint to Lower Control Arm Nuts .......................................................................................................................................... 70 Nm (52 ft. lbs.) Lower Ball Joint Stud Nut ........................................................................................................ .............................................................. 100 Nm (74 ft. lbs.) Upper Ball Joint Stud Nut ...................... .................................................................................................................................................. 50 Nm (37 ft. lbs.) Joint Wear Limit ................................................................................................................. ................................................................. 3.18 mm (0.125 inch) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 10386 Ball Joint: Testing and Inspection Ball Joint Inspection Tools Required ^ J8001 Dial Indicator Important: ^ The vehicle must rest on a level surface. ^ The vehicle must be stable. Do not rock the vehicle on the jack stands. ^ The upper control arm bumper must not contact the frame. 1. Raise and support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Support the lower control arm with a jack stand, as far outboard as possible, near the lower ball joint. Important: If a seal is cut or torn, replace the ball joint. 3. Wipe the ball joints clean. Check the seals for cuts or tears. 4. Check the wheel bearings for looseness. If looseness in the wheel bearings is present, refer to Wheel Bearings Diagnosis (Sealed). 5. Check the ball joints for horizontal looseness. 5.1. Position the J8001 dial indicator against the lowest outboard point on the wheel rim. 5.2. Rock the wheel in and out while reading the dial indicator. This shows horizontal looseness in both joints. 5.3. The dial indicator reading should be no more than 3.18 mm (0.125 inch). If the reading is too high, check the lower ball joints for vertical looseness. 6. Check the lower ball joints for wear and for vertical looseness using the following procedure: 6.1. Inspect by sight the lower ball joint for wear. The position of the housing into which the grease fitting is threaded indicates wear. This round housing projects 1.27 mm (0.050 inch) beyond the surface of the lower ball joint cover on a new ball joint. Under normal wear, the surface of the lower ball joint housing retreats inward very slowly. 6.2. First observe, then scrape a scale, a screwdriver, or a fingernail across the cover. If the round housing is flush with or inside of the cover surface, replace the lower ball joint. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 10387 7. Place a J8001 dial indicator (1) against the spindle in order to show vertical movement. 8. Pry between the lower control arm (2) and the outer bearing race (1) while reading the dial indicator. This shows vertical looseness in the ball joints. The lower ball joint is not preloaded and may show some looseness. 9. If the dial indicator reading is more than 3.18 mm (0.125 inch), replace the lower ball joint. 10. If the lower ball joint is within specifications, and there is too much horizontal looseness, check the upper control arm for wear. If you find any looseness or can twist the stud with your fingers, replace the upper control arm. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement (Coil Spring Suspension) Ball Joint: Service and Repair Lower Ball Joint Replacement (Coil Spring Suspension) Lower Ball Joint Replacement (Coil Spring Suspension) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the lower control arm. 4. Secure the lower control arm in a bench vice or equivalent. 5. Center punch the rivet heads. 6. Drill out the rivets. 7. Remove the lower ball joint. Installation Procedure 1. Install the ball joint to the lower control arm. 2. Install the replacement bolts to the lower control arm. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the nuts to the bolts. Tighten the nuts to 70 Nm (52 ft. lbs.). 4. Remove the lower control arm from the bench vice. 5. Install the lower control arm. 6. Install the tire and wheel tire assembly. 7. Remove the safety stands. 8. Lower the vehicle. 9. Verify the wheel alignment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement (Coil Spring Suspension) > Page 10390 Ball Joint: Service and Repair Lower Ball Joint Replacement (Torsion Bar Suspension) Lower Ball Joint Replacement (Torsion Bar Suspension) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the lower control arm. 4. Place the lower control arm in a bench vice. 5. Using a chisel, remove the 4 securing crimps from the ball joint body, the 15 series only. 6. Using a press, remove the ball joint from the lower control arm. Installation Procedure Important: Use the outer flange of the ball joint in order to press the ball joint into place. 1. Install the new ball joint using a press. 2. Place the lower control arm in a bench vice. 3. Using a punch, install 4 crimps to the ball joint. Use the replaced ball joint as a reference, the 15-series only. 4. Install the lower control arm. 5. Install the tire and wheel assembly. 6. Remove the safety stands. 7. Lower the vehicle. 8. Verify the wheel alignment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Specifications Control Arm: Specifications Front Upper Control Arm Nuts ...................................................................................................................... ............................................. 190 Nm (140 ft.lbs.) Lower Control Arm to Frame Nuts ................................................................................................................................................... 150 Nm (110 ft. lbs.) Rear Lower Control Arm Bolt ....................................................................................................................... .............................................. 120 Nm (89 ft. lbs.) Upper Control Arm Bolt ......................................... ............................................................................................................................ 105 Nm (77 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Control Arm: Service and Repair Front Upper Control Arm Replacement Upper Control Arm Replacement Tools Required ^ J43631 Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Disconnect the Real Time Damping (RTD) link rod from the sensor, if equipped. 4. Remove the retaining bolt for the brake hose and the wheel speed sensor brackets. 5. Remove the wheel drive shaft. 6. Remove the nut at the upper ball joint. Discard the nut. 7. Disconnect the upper control arm from the steering knuckle using the J43631 (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 10396 8. Remove the upper control arm nuts and the adjustment cams (2) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD). 9. Remove the upper control arm bolts (4) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. 10. Remove the upper control arm nuts and the adjustment cams (2) for the 25/35 Series 4WD. 11. Remove the upper control arm bolts (4) for the 25/35 Series 4WD. 12. Remove the upper control arm. Installation Procedure 1. Install the upper control arm. 2. Install the upper control arm bolts (4) for the 25/35 Series 4WD. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the upper control arm nuts and the adjustment cams (2) 25/35 Series 4WD. Tighten the nuts to 190 Nm (140 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 10397 4. Install the upper control arm bolts (4) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. 5. Install the upper control arm nuts and the adjustment cams (2) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. Tighten the nuts to 190 Nm (140 ft. lbs.). 6. Connect the upper control arm to the steering knuckle. 7. Install the wheel drive shaft. 8. Install the new nut to the upper ball joint stud. Tighten the nut to 50 Nm (37 ft. lbs.). 9. Install the retaining bolts for the brake hose and wheel speed sensor brackets. Tighten the bolts to 9 Nm (80 inch lbs.). 10. Connect the RTD link rod to the sensor, if equipped. 11. Install the tire and wheel. 12. Remove the safety stands. 13. Lower the vehicle. 14. Verify the wheel alignment. Lower Control Arm Replacement Lower Control Arm Replacement Tools Required ^ J43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the stabilizer shaft links from the lower control arm. 4. Remove the shock absorber lower nut and the bolt. 5. Remove the torsion bars. 6. Remove the wheel drive shaft. 7. Remove the lower ball joint stud nut. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 10398 8. Disconnect the lower ball joint stud from the steering knuckle using J43631 (1). 9. Remove the lower control arm nuts and the 15-series washers. 10. Remove the lower control arm bolts. 11. Remove the lower control arm nuts and the 25/35-series washers. 12. Remove the lower control arm bolts. 13. Remove the lower control arm. Installation Procedure 1. Install the lower control arm. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 10399 2. Install the lower control arm 15-series bolts. 3. Install the lower control arm 25/35-series bolts. 4. Install the washers with the shoulder facing the arm. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the lower control arm retaining nuts. Tighten the nuts to 150 Nm (110 ft. lbs.). 6. Install the wheel drive shaft. 7. Connect lower ball joint stud to the steering knuckle. 8. Install the nut to the lower ball joint stud. Tighten the nut to 100 Nm (74 ft. lbs.). 9. Install the torsion bars. 10. Install the shock absorber lower nut and bolt. 11. Install the stabilizer shaft links to the lower control arm. 12. Install the tire and wheel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 10400 13. Remove the safety stands. 14. Lower the vehicle. 15. Align the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 10401 Control Arm: Service and Repair Rear Rear Axle Upper Control Arm Replacement Rear Axle Upper Control Arm Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the Real Time Damping (RTD) sensor (if equipped). 3. Remove the upper control arm retaining nut and bolt from the frame bracket. 4. Remove the upper control arm retaining nut and bolt from the axle bracket. 5. Remove the upper control arm. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 10402 1. Install the upper control arm. 2. Install the upper control arm retaining bolt and nut to the axle bracket. 3. Install the upper control arm retaining bolt to the frame bracket. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not tighten the nuts unless the suspension is at the curb height position. 4. Install the upper control arm retaining nut. Tighten the upper control arm retaining bolts to 105 Nm (77 ft. lbs.). 5. Connect the (RTD) sensor (if equipped). 6. Lower the vehicle. Rear Axle Lower Control Arm Replacement Rear Axle Lower Control Arm Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the lower control arm retaining nuts. 3. Remove the lower control arm retaining bolt. 4. Remove the lower control arm. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 10403 1. Install the lower control arm. 2. Install the lower control arm retaining bolts. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not tighten the bolts unless the suspension is at the ride height. 3. Install the lower control arm retaining nut. Tighten the lower control arm retaining bolts to 120 Nm (89 ft. lbs.). 4. Remove the rear axle support. 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Body/Frame - Revised Crossmember/Body Bolt Service Cross-Member: Technical Service Bulletins Body/Frame - Revised Crossmember/Body Bolt Service Bulletin No.: 05-08-61-005 Date: April 29, 2005 SERVICE MANUAL UPDATE Subject: Revised Crossmember/Body Mount Bolt Installation Information Models: 1999-2005 Cadillac Full-Size Pickup and Utility Models 1999-2005 Chevrolet Full-Size Pickup and Utility Models 1999-2005 GMC Full-Size Pickup and Utility Models This bulletin is being issued to revise all repair procedures that include reinstalling the front engine crossmember-to-frame bolts or any body mount bolts in the Frame and Underbody sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Before reinstalling front engine crossmember-to-frame bolts or any body mount bolts, you must do the following: 1. Remove all traces of the original thread locking material. 2. Clean the threads of the bolt with denatured alcohol, or equivalent, and allow to dry. 3. Apply Thread locker, P/N 12345493, (Canadian P/N 10953488). Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Engine Front Crossmember Replacement (4WD) Cross-Member: Service and Repair Engine Front Crossmember Replacement (4WD) Engine Front Crossmember Replacement (4WD) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the differential carrier shield. 3. Remove the bolts retaining the crossmember to the frame. 4. Remove the crossmember from the vehicle. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Engine Front Crossmember Replacement (4WD) > Page 10410 1. Install the crossmember to the vehicle. 2. Perform the following procedure before installing the bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Notice: Refer to Fastener Notice. 3. Install the bolts retaining the crossmember to the frame. Tighten the crossmember retaining bolts to 120 N.m (88 lb ft). 4. Install the differential carrier shield. 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Engine Front Crossmember Replacement (4WD) > Page 10411 Cross-Member: Service and Repair Transmission Support Replacement Transmission Support Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Remove the nut retaining the transmission mount to the transmission support. 4. Raise the rear of the transmission. 5. Remove the bolts and the nuts retaining the transmission support to the frame. (15 series) 6. Remove the bolts and the nuts retaining the transmission support to the frame. (25/35 series) 7. Remove the transmission support from the frame. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Engine Front Crossmember Replacement (4WD) > Page 10412 1. Install the transmission support to the frame. (15 series) 2. Install the transmission support to the frame. (25/35 series) Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts and the nuts in order to retain the transmission support to the frame. Tighten the nuts to 95 N.m (70 lb ft). 4. Lower the rear of the transmission. 5. Install the transmission mount to the transmission support. 6. Install the nuts in order to retain the transmission mount to the transmission support. Tighten the nuts to 50 N.m (36 lb ft). 7. Remove the transmission jack. 8. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Steering Knuckle Replacement Tools Required ^ J43631 Ball Joint Separating Tool Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Disconnect the Real Time Damping (RTD) link rod from the sensor, if equipped. 4. Unload the torsion bars. 5. Remove the wheel hub and bearing assembly. 6. Disconnect the outer tie rod to the steering knuckle. 7. Remove the brake hose bracket retaining bolt from the steering knuckle. 8. Remove the upper control arm retaining nut and separate the upper ball joint from the steering knuckle (2) using the J43631 (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 10416 9. Remove the lower control arm retaining nut. Separate the lower ball joint from the steering knuckle (2) using the J43631(1). 10. Remove the steering knuckle. Installation Procedure 1. Clean all grease and contaminants from the tapered section and the threads of the upper ball joint, the lower ball joint, and the tie rod end. 2. Clean and inspect the taper holes and the mounting surfaces of the steering knuckle. If any of the tapered holes are elongated, out of round, or damaged, replace the steering knuckle. 3. Install the steering knuckle. Notice: Refer to Fastener Notice in Service Precautions. 4. Connect the lower ball joint to the steering knuckle and install the retaining nut. Tighten the lower control arm retaining nut to 100 Nm (74 ft. lbs.). 5. Connect the upper ball joint to the steering knuckle and install the retaining nut. Tighten the upper control arm retaining nut to 50 Nm (37 ft. lbs.). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 10417 6. Install the brake hose and the bracket retaining bolt to the steering knuckle Tighten the bolt to 9 Nm (80 inch lbs.). 7. Connect the outer tie rod to the steering knuckle. 8. Install the wheel hub and bearing assembly. 9. Connect the RTD link rod to the sensor, if equipped. 10. Install the tire and wheel. 11. Load the torsion bars. 12. Align the vehicle. 13. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications Lateral Stabilizer Rod: Specifications Track Bar Bolt ...................................................................................................................................... .................................................. 105 Nm (77 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 10421 Lateral Stabilizer Rod: Service and Repair Track Bar Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the rear axle. 3. Remove the park brake cable retaining clips to remove the parking brake cable from the track bar. 4. Remove the track bar retaining nuts. 5. Remove the track bar retaining bolts. 6. Remove the track bar from the vehicle. Installation Procedure 1. Install the track bar to the vehicle. 2. Install the track bar retaining bolts. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 10422 Notice: Refer to Fastener Notice in Service Precautions. Important: Do not tighten the bolts unless the suspension is at the curb height position. 3. Install the track bar retaining nuts. Tighten the bolts to 105 Nm (77 ft. lbs.). 4. Install the parking brake cable and retaining clips to the track bar. 5. Remove the rear axle support. 6. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Electronic Suspension Control Module to Bracket .............................................................................................................................. 1.6 Nm (14 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > C1 > Page 10429 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > C1 > Page 10430 Suspension Control Module: Diagrams C3 Suspension Control Module - C3 Part 1 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > C1 > Page 10431 Part 2 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > Page 10432 Suspension Control Module: Service and Repair Electronic Suspension Control Module Replacement (Tahoe/Yukon/Escalade) Removal Procedure 1. Remove the right side interior trim panel. 2. Disconnect the electrical connectors from the module. 3. Remove the screw. 4. Slide the module from the bracket and remove the module from the vehicle. Installation Procedure 1. Install the module to the vehicle by sliding the module into the bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screw. Tighten the screw to 1.6 Nm (14 inch lbs.). 3. Connect the electrical connectors to the module. 4. If you are replacing the module you must recalibrate the module by performing the following procedure: ^ Connect the scan tool to the Data Line Connector (DLC). ^ Turn the ignition ON with the engine OFF. ^ Proceed per the instructions on the scan tool readout. 5. Install the right side interior trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications Ride Height Sensor: Specifications Front Position Sensor Link Bracket Bolt ................................................................................................................................................. 9 Nm (80 inch lbs.) Front Position Sensor Mounting Bolt .................................................................................................................................................. 12 Nm (106 inch lbs.) Rear Position Sensor Link Bracket Bolt ................................................................................................................................................... 25 Nm (18 ft. lbs.) Rear Position Sensor Mounting Bolt ................................................................................................................................................... 12 Nm (106 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Diagrams > LF Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Diagrams > LF > Page 10439 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Diagrams > LF > Page 10440 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Diagrams > LF > Page 10441 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Front Position Sensor Link Assembly Replacement - Electronic Suspension Ride Height Sensor: Service and Repair Front Position Sensor Link Assembly Replacement Electronic Suspension Front Position Sensor Link Assembly Replacement - Electronic Suspension Tools Required ^ J38185 Spring Hose Clamp Pliers Removal Procedure Important: Do not attempt to pry the link rod from the Real Time Damping (RTD) ball stud. If the link rod needs to be replaced or disconnected you must use the following procedure. 1. Remove the RTD sensor from the vehicle. 2. While supporting the sensor lever by hand, twist the link rod to remove it from the ball stud. 3. Remove the link rod from the mounting bracket ball stud. Installation Procedure 1. Using the J38185 install to link rod to the ball stud on the sensor lever and the mounting bracket. 2. Install the RTD sensor to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Front Position Sensor Link Assembly Replacement - Electronic Suspension > Page 10444 Ride Height Sensor: Service and Repair Rear Position Sensor Link Assembly Replacement Electronic Suspension Rear Position Sensor Link Assembly Replacement - Electronic Suspension Tools Required ^ J38185 Spring Hose Clamp Pliers Removal Procedure Important: Do not attempt to pry the link rod from the Real Time Damping (RTD) ball stud. If the link rod needs to be replaced or disconnected you must use the following procedure. 1. Remove the RTD sensor from the vehicle. 2. While supporting the sensor lever by hand, twist the link rod to remove it from the ball stud. 3. Remove the link rod from the frame bracket ball stud. Installation Procedure 1. Using the J38185 install to link rod to the ball stud on the sensor lever and the frame bracket. 2. Install the RTD sensor to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Steering Wheel Speed/Position Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Steering Wheel Speed/Position Sensor - W/ RTD Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Steering Wheel Speed/Position Sensor - W/ RTD > Page 10450 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Page 10451 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Removal Procedure 1. Set the front wheels in the straight-ahead position. Set the steering wheel in the LOCKED position. 2. Disable the Supplemental Inflatable Restraint (SIR). 3. Remove the nut and the bolt (1) from the upper intermediate shaft connection and slide the intermediate steering shaft down. 4. Remove the position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. Important: Do not apply force to the sensor and the bearing in a sideways direction. 5. Remove the position sensor and bearing assembly from the steering column jacket by pulling the assembly straight out. 6. Remove the position sensor from the clips in the bearing assembly. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams > Page 10452 1. Install the position sensor into the bearing assembly. Important: Do not apply force to the sensor and the bearing in a sideways direction. 2. Install the bearing into the steering column jacket. 2.1. Align the notches on the bearing and the column jacket. 2.2. Seat the bearing fulling into the jacket. 3. Connect the position sensor connector. Notice: Refer to Fastener Notice in Service Precautions. 4. Slide the shaft up to install the bolt and the nut (1) to the upper intermediate shaft to steering column connection. Tighten the upper intermediate shaft connection to 47 Nm (35 ft. lbs.). 5. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Control Pressure Sensor/Switch > Component Information > Service and Repair Suspension Control Pressure Sensor/Switch: Service and Repair "For information regarding this component please refer to air dryer suspension control service and repair" Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Suspension - Revised Stabilizer Link Service/Torque Stabilizer Link: Technical Service Bulletins Suspension - Revised Stabilizer Link Service/Torque Bulletin No.: 05-03-08-006 Date: April 12, 2005 SERVICE MANUAL UPDATE Subject: Revised Stabilizer Shaft Link Replacement Procedure and Fastener Tightening Specifications Models: 1999-2005 Chevrolet and GMC Full Size Pickup and Utility Models 2003-2005 HUMMER H2 This bulletin is being issued to revise the Stabilizer Shaft Link Replacement Procedure and Fastener Tightening Specifications in the Front Suspension sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following revision affects both the Fastener Tightening Specifications and the Stabilizer Shaft Link Replacement procedure. Pickup and Utility Models : Stabilizer Shaft Link Nuts - 10 Nm (89 lb in) Continue tightening the nut until 2 to 4 threads protrude above the nut. H2 : Stabilizer Shaft Link Nuts - 14 Nm (124 lb in) Continue tightening the nut until 2 to 4 threads protrude above the nut. The following Notice has been added to the Stabilizer Shaft Link Replacement procedure. Note: To avoid stabilizer shaft damage due to loss of clamp load, the threads of the link bolt must protrude 2 to 4 threads above the nut after the specified torque is achieved. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Page 10461 Stabilizer Link: Specifications The content of this article reflects the changes identified in TSB 05-03-08-006. Front Stabilizer Shaft Link Nuts .................................................................................................................... ............................................. 10 Nm (89 inch lbs.) Continue tightening the nut until 2-4 threads protrude above the nut. Rear Stabilizer Shaft Link Nuts .................................................................................................................... ................................................. 65 Nm (48 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Page 10462 Stabilizer Link: Service and Repair The content of this article reflects the changes identified in TSB 05-03-08-006. Stabilizer Shaft Link Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft nut (1) from the link bolt. 3. Remove the stabilizer shaft link bolt (3). 4. Remove the stabilizer shaft link insulators and spacers (2). 5. Inspect all of the parts for wear and damage. Installation Procedure 1. Install the stabilizer shaft link insulators and spacers (2). 2. Install the stabilizer shaft link bolts (3). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the stabilizer shaft nut (1) to the link bolt. Tighten the nut to 10 Nm (89 inch lbs.). Continue tightening the nut until 2-4 threads protrude above the nut. 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Service and Repair Air Dryer: Service and Repair Automatic Level Control Air Dryer and Pressure Sensor Replacement Removal Procedure 1. Remove the automatic level control air compressor from the vehicle. 2. Clean the area around the connection of the automatic level control air dryer to the automatic level control air compressor body. 3. Disconnect the electrical connector from the pressure sensor. 4. Remove the air dryer/pressure sensor assembly retaining screw. 5. Push the air dryer/pressure sensor assembly in while rotating the air dryer/pressure sensor assembly clockwise until the assembly detaches from the automatic level control air compressor body. 6. Remove the automatic level control air dryer from the automatic level control air compressor. Installation Procedure 1. Install the automatic level control air dryer to the automatic level control air compressor. 2. Push the air dryer/pressure sensor assembly in while rotating the air dryer/pressure sensor assembly counterclockwise until the assembly attaches to the automatic level control air compressor body. 3. Install the air dryer/pressure sensor assembly retaining screw. 4. Connect the electrical connector to the pressure sensor. 5. Install the automatic level control air compressor to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Specifications Air Line: Specifications Air Line Tube Repair Nut ..................................................................................................................... ................................................. 8 Nm (70 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Specifications > Page 10470 Air Line: Service and Repair Air Line Tubing Repair 1. Locate the leaking area with soap and water or a stethoscope. 2. Cut and remove the leaking line (2) section. 3. Remove the plastic retainer pin from one of the nuts. 4. Slide the air line tube onto the nut until the line bottoms in the rubber seal (5). Notice: Refer to Fastener Notice in Service Precautions. 5. Hold the air line tube in position. Tighten the air line tube repair nut to 8 Nm (70 inch lbs.). 6. Install the air line tube to the other end of the coupling. 7. Repeat Steps 3 through 5. Important: Ensure that the repaired air line tube is secured in a location where the line is not pinched, or kinked, and will not contact the exhaust system. 8. Install the air line tube to the vehicle. 9. Inflate the real time damping level control system and inspect for leaks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications Compressor/Pump: Specifications Air Compressor to Frame Nuts ............................................................................................................ ..................................................... 15 Nm (11 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications > Page 10474 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions Compressor/Pump: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10477 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10478 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10479 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10480 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10481 Compressor/Pump: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10482 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10483 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10484 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10485 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10486 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10487 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10488 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10489 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10490 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10491 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10492 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10493 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10494 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10495 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10496 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10497 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10498 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10499 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10500 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10501 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10502 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10503 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10504 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10505 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10506 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Diagram Information and Instructions > Page 10507 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Page 10508 Compressor/Pump: Service and Repair Air Compressor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. Important: Clean the components and the surrounding area to prevent dirt from entering the air system before disconnecting the air hose from the air compressor. 2. Disconnect the air tube (1) from the air dryer. 3. Disconnect the electrical connection (2). 4. Remove the air inlet and hose (1) from the fuel filler neck bracket. 5. Loosen the mounting nuts. 6. Slide the air compressor (2) rearward to clear the frame slots. 7. Remove the air compressor from the vehicle. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Page 10509 1. Install the air compressor (2) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Slide the air compressor forward to secure the fasteners into the frame slots and tighten the mounting nuts. Tighten the nuts to 15 Nm (11 ft. lbs.). 3. Install the air inlet hose (1) to the fuel filler neck bracket. 4. Connect the air tube (1) to the air dryer. 5. Connect the electrical connection (2). Important: Before driving the vehicle, turn the ignition on and wait approximately 45 seconds. This will ensure that the air adjustable shock absorbers are filled with residual pressure. 6. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Control Solenoid Valve > Component Information > Technical Service Bulletins > Customer Interest for Ride Control Solenoid Valve: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 Ride Control Solenoid Valve: Customer Interest Suspension - Service Ride Control Message/DTC C0580 Bulletin No.: 03-03-11-001 Date: July 22, 2003 TECHNICAL Subject: Service Ride Control Message Displayed, DTC C0580 Set (Replace Right Front Shock Absorber Solenoid Connector and Install New A/C Suction Hose and Auxiliary A/C Evaporator Hose) Models: 2002-2003 Cadillac Escalade 2003 Cadillac Escalade ESV 2001-2003 Chevrolet Suburban, Tahoe 2001-2003 GMC Yukon, Yukon XL with Rear Air Conditioning System (RPO C69) and Real Time Damping Chassis Package (RPO Z55) Condition Some customers may comment on the Service Ride Control message being displayed. Upon investigation, the technician may find DTC C0580 set. Cause Poor clearance between the auxiliary A/C evaporator hose and the right front shock absorber damper solenoid connector may be the cause of this condition. Contact may occur damaging the connector and causing a poor connection at the damper solenoid. Correction Replace the right front shock absorber solenoid connector and install a new A/C suction hose and auxiliary A/C evaporator hose. These new A/C hoses will provide proper routing to prevent contact between the auxiliary A/C evaporator hose and the right front shock absorber damper solenoid connector. Use the procedure listed below. 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 3. Remove the right front wheel assembly. 4. Remove the right front wheelhouse panel. 5. Remove the nut and the auxiliary evaporator hose from the accumulator line block. 6. Remove the nut and the suction hose from the accumulator. 7. Remove the bolt and the suction hose from the compressor. 8. Install the new suction hose and bolt to the compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). 9. Install the new suction hose and nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 10. Release 4 line retaining clamps, starting at the wheelhouse and along the underbody towards the rear of vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Control Solenoid Valve > Component Information > Technical Service Bulletins > Customer Interest for Ride Control Solenoid Valve: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 > Page 10518 11. From under the vehicle, mark the location on the auxiliary evaporator line where the line will be cut. Using the forward running board bracket as a reference, mark the location inline with the bracket-to-body bolt (1). If the vehicle is not equipped with running boards, mark the location inline with the bolt hole. 12. Using a tubing cutter, cut the marked section of the auxiliary evaporator line. 13. Remove the front section of the auxiliary evaporator hose from the vehicle and discard. 14. Install the new front section of the auxiliary evaporator hose into the vehicle. 15. On both sections of the auxiliary evaporator line, cut back the plastic coating approximately 76 mm (3 in). 16. Splice in the new front section of the auxiliary evaporator hose using J 41425 A/C Line Repair Kit and J 41425-750 splice. Refer to the Heater and A/C Pipe Repair-Auxiliary procedure in the Service Manual. 17. Install the auxiliary evaporator hose to the accumulator line block and nut. Tighten Tighten the nut to 16 N.m (12 lb ft). 18. Secure the line retaining clamps. 19. Install the wheelhouse panel. 20. Install the wheel assembly. 21. Lower the vehicle. 22. Inject the oil into the A/C system that was removed during the recovery process using J 45037 A/C Oil Injection Kit. 23. Evacuate and recharge the refrigerant. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. 24. Leak test the fitting and splice using J 39400-A Halogen Leak Detector. 25. Replace the right front shock absorber solenoid connector using service connector, P/N 88986417. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Control Solenoid Valve > Component Information > Technical Service Bulletins > Customer Interest for Ride Control Solenoid Valve: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 > Page 10519 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Control Solenoid Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ride Control Solenoid Valve: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 Ride Control Solenoid Valve: All Technical Service Bulletins Suspension - Service Ride Control Message/DTC C0580 Bulletin No.: 03-03-11-001 Date: July 22, 2003 TECHNICAL Subject: Service Ride Control Message Displayed, DTC C0580 Set (Replace Right Front Shock Absorber Solenoid Connector and Install New A/C Suction Hose and Auxiliary A/C Evaporator Hose) Models: 2002-2003 Cadillac Escalade 2003 Cadillac Escalade ESV 2001-2003 Chevrolet Suburban, Tahoe 2001-2003 GMC Yukon, Yukon XL with Rear Air Conditioning System (RPO C69) and Real Time Damping Chassis Package (RPO Z55) Condition Some customers may comment on the Service Ride Control message being displayed. Upon investigation, the technician may find DTC C0580 set. Cause Poor clearance between the auxiliary A/C evaporator hose and the right front shock absorber damper solenoid connector may be the cause of this condition. Contact may occur damaging the connector and causing a poor connection at the damper solenoid. Correction Replace the right front shock absorber solenoid connector and install a new A/C suction hose and auxiliary A/C evaporator hose. These new A/C hoses will provide proper routing to prevent contact between the auxiliary A/C evaporator hose and the right front shock absorber damper solenoid connector. Use the procedure listed below. 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 3. Remove the right front wheel assembly. 4. Remove the right front wheelhouse panel. 5. Remove the nut and the auxiliary evaporator hose from the accumulator line block. 6. Remove the nut and the suction hose from the accumulator. 7. Remove the bolt and the suction hose from the compressor. 8. Install the new suction hose and bolt to the compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). 9. Install the new suction hose and nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 10. Release 4 line retaining clamps, starting at the wheelhouse and along the underbody towards the rear of vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Control Solenoid Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ride Control Solenoid Valve: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 > Page 10525 11. From under the vehicle, mark the location on the auxiliary evaporator line where the line will be cut. Using the forward running board bracket as a reference, mark the location inline with the bracket-to-body bolt (1). If the vehicle is not equipped with running boards, mark the location inline with the bolt hole. 12. Using a tubing cutter, cut the marked section of the auxiliary evaporator line. 13. Remove the front section of the auxiliary evaporator hose from the vehicle and discard. 14. Install the new front section of the auxiliary evaporator hose into the vehicle. 15. On both sections of the auxiliary evaporator line, cut back the plastic coating approximately 76 mm (3 in). 16. Splice in the new front section of the auxiliary evaporator hose using J 41425 A/C Line Repair Kit and J 41425-750 splice. Refer to the Heater and A/C Pipe Repair-Auxiliary procedure in the Service Manual. 17. Install the auxiliary evaporator hose to the accumulator line block and nut. Tighten Tighten the nut to 16 N.m (12 lb ft). 18. Secure the line retaining clamps. 19. Install the wheelhouse panel. 20. Install the wheel assembly. 21. Lower the vehicle. 22. Inject the oil into the A/C system that was removed during the recovery process using J 45037 A/C Oil Injection Kit. 23. Evacuate and recharge the refrigerant. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. 24. Leak test the fitting and splice using J 39400-A Halogen Leak Detector. 25. Replace the right front shock absorber solenoid connector using service connector, P/N 88986417. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Control Solenoid Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ride Control Solenoid Valve: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 > Page 10526 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Specifications Ride Height Sensor: Specifications Front Position Sensor Link Bracket Bolt ................................................................................................................................................. 9 Nm (80 inch lbs.) Front Position Sensor Mounting Bolt .................................................................................................................................................. 12 Nm (106 inch lbs.) Rear Position Sensor Link Bracket Bolt ................................................................................................................................................... 25 Nm (18 ft. lbs.) Rear Position Sensor Mounting Bolt ................................................................................................................................................... 12 Nm (106 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Diagrams > LF Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Diagrams > LF > Page 10532 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Diagrams > LF > Page 10533 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Diagrams > LF > Page 10534 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Front Position Sensor Link Assembly Replacement - Electronic Suspension Ride Height Sensor: Service and Repair Front Position Sensor Link Assembly Replacement Electronic Suspension Front Position Sensor Link Assembly Replacement - Electronic Suspension Tools Required ^ J38185 Spring Hose Clamp Pliers Removal Procedure Important: Do not attempt to pry the link rod from the Real Time Damping (RTD) ball stud. If the link rod needs to be replaced or disconnected you must use the following procedure. 1. Remove the RTD sensor from the vehicle. 2. While supporting the sensor lever by hand, twist the link rod to remove it from the ball stud. 3. Remove the link rod from the mounting bracket ball stud. Installation Procedure 1. Using the J38185 install to link rod to the ball stud on the sensor lever and the mounting bracket. 2. Install the RTD sensor to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Front Position Sensor Link Assembly Replacement - Electronic Suspension > Page 10537 Ride Height Sensor: Service and Repair Rear Position Sensor Link Assembly Replacement Electronic Suspension Rear Position Sensor Link Assembly Replacement - Electronic Suspension Tools Required ^ J38185 Spring Hose Clamp Pliers Removal Procedure Important: Do not attempt to pry the link rod from the Real Time Damping (RTD) ball stud. If the link rod needs to be replaced or disconnected you must use the following procedure. 1. Remove the RTD sensor from the vehicle. 2. While supporting the sensor lever by hand, twist the link rod to remove it from the ball stud. 3. Remove the link rod from the frame bracket ball stud. Installation Procedure 1. Using the J38185 install to link rod to the ball stud on the sensor lever and the frame bracket. 2. Install the RTD sensor to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Electronic Suspension Control Module to Bracket .............................................................................................................................. 1.6 Nm (14 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Diagrams > C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Diagrams > C1 > Page 10543 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Diagrams > C1 > Page 10544 Suspension Control Module: Diagrams C3 Suspension Control Module - C3 Part 1 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Diagrams > C1 > Page 10545 Part 2 of 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Diagrams > Page 10546 Suspension Control Module: Service and Repair Electronic Suspension Control Module Replacement (Tahoe/Yukon/Escalade) Removal Procedure 1. Remove the right side interior trim panel. 2. Disconnect the electrical connectors from the module. 3. Remove the screw. 4. Slide the module from the bracket and remove the module from the vehicle. Installation Procedure 1. Install the module to the vehicle by sliding the module into the bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screw. Tighten the screw to 1.6 Nm (14 inch lbs.). 3. Connect the electrical connectors to the module. 4. If you are replacing the module you must recalibrate the module by performing the following procedure: ^ Connect the scan tool to the Data Line Connector (DLC). ^ Turn the ignition ON with the engine OFF. ^ Proceed per the instructions on the scan tool readout. 5. Install the right side interior trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Pressure Sensor/Switch > Component Information > Service and Repair Suspension Control Pressure Sensor/Switch: Service and Repair "For information regarding this component please refer to air dryer suspension control service and repair" Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Leaf Spring Bushing > Component Information > Service and Repair Leaf Spring Bushing: Service and Repair Spring Bushing Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the leaf spring assembly from vehicle. 3. Remove the bushing from the leaf spring using the following procedure: 3.1. Place the leaf spring in a press. 3.2. Press the bushing out. 3.3. Clean the spring bushing bore of any foreign or old bushing material. Installation Procedure 1. Apply rubber lubricant to the bushing (1) and spring eye (2). 2. Install the bushing to the leaf spring. 2.1. Place the leaf spring in a press. 2.2. Press the bushing into the spring. 3. Install the leaf spring assembly to the vehicle. 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle > Component Information > Specifications Shackle: Specifications Shackle to Frame Bracket Nut ............................................................................................................. ..................................................... 95 Nm (70 ft. lbs.) Shackle to Spring Nut ...................................... ......................................................................................................................................... 95 Nm (70 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle > Component Information > Specifications > Page 10557 Shackle: Service and Repair Spring Shackle Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the leaf spring assembly from vehicle. 3. Remove the shackle nut and the bolt from the spring. Installation Procedure 1. Install the shackle to the spring. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the shackle nut and bolt to the spring. Tighten the shackle nut to 95 Nm (70 ft. lbs.). 3. Install the leaf spring assembly to the vehicle. 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-08-002B > Nov > 05 > Suspension Rattles/Squeaks From Front of Vehicle Suspension Strut / Shock Absorber: Customer Interest Suspension - Rattles/Squeaks From Front of Vehicle Bulletin No.: 03-03-08-002B Date: November 30, 2005 TECHNICAL Subject: Rattle/Squeak from Front of Vehicle (Replace Lower Portion of Upper Insulator Assembly) Models: 2002-2005 Cadillac Escalade, Escalade EXT 2003-2005 Cadillac Escalade ESV 2000-2005 Chevrolet Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 2000-2005 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the correction and parts information. Please discard Corporate Bulletin Number 03-03-08-002A (Section 03 - Suspension). Condition Some customers may comment on a rattle or squeak type noise coming from the front of the vehicle. Cause The front shock absorber plastic pilot ring may be wearing out, causing the shock to misalign in the insulator. Correction DO NOT replace the shock. Replace the lower portion, P/N 15834275 , of the upper insulator assembly using the procedure listed below. This new insulator has a taller plastic pilot ring that is attached to the metal sleeve to aid in the proper alignment of the insulators. 1. Remove the front shock absorber. Refer to the Shock Absorber Replacement procedure in the Front Suspension sub-section of the Service Manual. 2. Remove the lower portion of the upper insulator from the shock and discard. 3. Install the new lower portion of the upper insulator to the shock. Important: Be sure to center the shock in the frame bracket and tighten the upper mounting nut when the vehicle is on the ground. 4. Install the front shock absorber. Refer to the Shock Absorber Replacement procedure in the Front Suspension sub-section of the Service Manual. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-08-002B > Nov > 05 > Suspension Rattles/Squeaks From Front of Vehicle > Page 10566 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information > Page 10572 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 03-03-08-002B > Nov > 05 > Suspension - Rattles/Squeaks From Front of Vehicle Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Rattles/Squeaks From Front of Vehicle Bulletin No.: 03-03-08-002B Date: November 30, 2005 TECHNICAL Subject: Rattle/Squeak from Front of Vehicle (Replace Lower Portion of Upper Insulator Assembly) Models: 2002-2005 Cadillac Escalade, Escalade EXT 2003-2005 Cadillac Escalade ESV 2000-2005 Chevrolet Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 2000-2005 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the correction and parts information. Please discard Corporate Bulletin Number 03-03-08-002A (Section 03 - Suspension). Condition Some customers may comment on a rattle or squeak type noise coming from the front of the vehicle. Cause The front shock absorber plastic pilot ring may be wearing out, causing the shock to misalign in the insulator. Correction DO NOT replace the shock. Replace the lower portion, P/N 15834275 , of the upper insulator assembly using the procedure listed below. This new insulator has a taller plastic pilot ring that is attached to the metal sleeve to aid in the proper alignment of the insulators. 1. Remove the front shock absorber. Refer to the Shock Absorber Replacement procedure in the Front Suspension sub-section of the Service Manual. 2. Remove the lower portion of the upper insulator from the shock and discard. 3. Install the new lower portion of the upper insulator to the shock. Important: Be sure to center the shock in the frame bracket and tighten the upper mounting nut when the vehicle is on the ground. 4. Install the front shock absorber. Refer to the Shock Absorber Replacement procedure in the Front Suspension sub-section of the Service Manual. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 03-03-08-002B > Nov > 05 > Suspension - Rattles/Squeaks From Front of Vehicle > Page 10577 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information > Page 10583 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Page 10584 Suspension Strut / Shock Absorber: Specifications Front Shock Absorber Tension Nut ............................................................................................................... ................................................. 20 Nm (15 ft. lbs.) Shock Absorber to Lower Control Arm Nut ......................................................................................................................................... 80 Nm (59 ft. lbs.) Rear Shock Absorber Nuts ........................................................................................................................... ................................................. 95 Nm (70 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Suspension Strut / Shock Absorber: Service and Repair Front Suspension Shock Absorber Replacement Shock Absorber Replacement Removal Procedure Notice: The front shock absorbers of the vehicle are multifunctional. In addition to contributing to a smooth ride they also provide the only stop to the front suspension when fully extended. Therefore, when servicing the shock absorber, service replacement shock absorbers must be equivalent to original shock absorbers in both extended length and strength. Use of shocks not complying to original equipment or strength could result in suspension over-travel or shock breakage. Suspension over-travel may result in suspension component breakage. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the lower control arm with a jack stand. 3. Disconnect the (RTD) link rod from the sensor, if equipped. 4. Disconnect the electrical connector if equipped with selectable ride, if equipped. 5. Grasp the connector lock tabs (1, 2). Rotate the connector tabs counterclockwise until the connector is unlocked. 6. Disengage the connector from the tennon by firmly pulling the connector up. 7. Hold the tennon end with a wrench while removing the nut. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 10587 8. Remove the nut. 9. Remove the upper insulator (1). Do not discard the plastic pilot ring (2). 10. Remove the shock absorber mounting bolt at the lower control arm, 15 Series. 11. Remove the shock absorber mounting bolt (2) at the lower control arm, 25/35 Series. 12. Remove the shock absorber. Installation Procedure 1. Install the shock absorber. Insert the stem through the hole in the shock bracket on the frame. 2. Align the shock absorber with the mounting holes in the lower control arm, 15 Series. 3. Align the shock absorber with the mounting holes in the lower control arm, 25/35 Series. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 10588 4. Install the shock absorber through the bolt (2) to the lower control arm. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the shock absorber through the bolt nut (3). Tighten the nut to 80 Nm (59 ft. lbs.). Important: The upper insulators are substantially larger that the lower insulators. The upper insulator (1) must be installed above the shock mounting bracket on the frame. The plastic pilot ring (2) will assist the alignment of the isolators. 6. Install the upper insulator to the shock absorber. 7. Install the nut to the tennon end. Do not tighten the nut. 8. Connect the RTD link rod to the sensor, if equipped. 9. Remove the safety stands. 10. Lower the vehicle. 11. Hold the tennon end with a wrench while torquing the nut. Tighten the nut to 20 Nm (15 ft. lbs.). 12. Connect the electrical connector using the following procedure if equipped with selectable ride, if equipped. 12.1. Verify that the connector is unlocked. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 10589 12.2. Align the connector so that the tabs (1) are perpendicular to the wrench flats on the tennon end. 12.3. Engage the connector to the tennon by firmly pushing the connector down. 12.4. Grasp the connector lock tabs (1, 2). Rotate the connector counterclockwise. 13. The connector is locked into place when you hear an audible snap and the tabs (1, 2) are aligned. 14. Dispose of the shock absorber. Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Caution: To prevent personal injury, wear safety glasses when centerpunching and trailing the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 10590 1. Make an indentation 10 mm (0.4 inch) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 10591 Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber Shock Absorber Replacement (15 Series Utility W/G65) Shock Absorber Replacement (15 Series Utility w/G65) Removal Procedure Important: This shock absorber is a very high pressure gas charged component. Never attempt to tether or manually compress the shock. Replacement shocks are supplied in the fully extended position. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the rear axle. 3. Remove the upper shock absorber nut and the bolt. 4. Remove the lower shock absorber nut and the bolt. 5. Lower the rear axle to allow the removal of the shock absorber. 6. Remove the shock absorber. Installation Procedure 1. Install the shock absorber. 2. Install the upper shock absorber nut and bolt. 3. Raise the rear axle to allow the installation of the lower through bolt. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the lower shock absorber nut and bolt. Tighten the nuts to 95 Nm (70 ft. lbs.). 5. Remove the support from the rear axle. 6. Remove the safety stands. 7. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 10592 Shock Absorber Replacement (15 Series Utility) Shock Absorber Replacement (15 Series Utility) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector and air line if equipped with Real Time Damping (RTD). 3. Support the rear axle. 4. Disconnect the RTD sensor (if equipped). 5. Remove the upper shock absorber nut and the bolt. 6. Remove the lower shock absorber nut and the bolt. 7. Remove the shock absorber. Installation Procedure 1. Install the shock absorber. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 10593 2. Install the upper shock absorber nut and bolt. 3. Install the lower shock absorber nut and bolt. Tighten the nuts to 95 Nm (70 ft. lbs.). 4. Connect the electrical connector and air line if equipped with RTD. 5. Connect the RTD sensor, if equipped. 6. Remove the support from the rear axle. 7. Remove the safety stands. 8. Lower the vehicle. Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Caution: To prevent personal injury wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 10594 1. Make an indentation 10 mm (0.4 inch) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair Torsion Bar: Service and Repair Torsion Bar Replacement Tools Required ^ J36202 Torsion Bar Unloading/Loading Tool Removal Procedure Notice: Use care when handling the torsion bars in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the torsion bars. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Install the J36202 to the adjustment arm and the crossmember. 3. Increase the tension on the adjustment arm until the load is removed from the adjustment bolt and the adjuster nut. Important: Mark the adjustment bolt and count the number of times that is required to remove the adjustment bolt. 4. Remove the adjustment bolt (3) and the adjuster nut (4). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Page 10598 5. Remove the adjustment bolt (3) and the adjuster nut (4), for vehicles with MN8, MT1 and MW3. 6. Remove the J36202, allowing the torsion bar to unload. 7. Remove the adjustment arm by sliding the torsion bar forward until the torsion bar clears the adjustment arm. Use your hand to support the adjustment arm as the adjustment arm releases from the torsion bar. 8. Remove the torsion bar crossmember bolts (4) from the weld nuts (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Page 10599 9. Remove the upper link mounting nuts (1) and the bolts (2). 10. Remove the torsion bar crossmember. Important: Note the position of the torsion bars as the left and right bars are different. 11. Remove the torsion bars from the vehicle. Installation Procedure 1. Install the torsion bars to the lower control arm. 2. Install the torsion bar crossmember. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Page 10600 3. Install the torsion bar crossmember bolts (1) to the weld nuts (4). Tighten the bolt to 95 Nm (70 ft. lbs.). 4. Install the upper link mounting nuts and the bolts (3). Tighten the nut to 95 Nm (70 ft. lbs.). 5. While supporting the adjustment arm, slide the torsion bar rearward until the torsion bar fully engages the adjustment arm. 6. Install the J36202 to the adjustment arm and the crossmember. 7. Increase the tension on the adjustment arm in order to load the torsion bar. Important: Install the adjustment bolt the same amount of turns that were required to remove the bolt during removal. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Page 10601 8. Install the adjustment bolt (3) and the adjuster nut (4). 9. Install the adjustment bolt (3) and the adjuster nut (4), for vehicles with MN8, MT1 AND MW3. 10. Remove the J36202 releasing the tension on the torsion bar until the load is taken up by the adjustment bolt. 11. Remove the safety stands. 12. Lower the vehicle. 13. Measure the Z height. 14. Turn the adjustment bolt (2) clockwise to increase the Z height and counterclockwise to decrease the Z height. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Drive Train - Revised Wheel Bearing Adjustment Procedure Wheel Bearing: Technical Service Bulletins Drive Train - Revised Wheel Bearing Adjustment Procedure File In Section: 04 - Driveline Axle Bulletin No.: 02-04-20-002 Date: May, 2002 SERVICE MANUAL UPDATE Subject: Revised Wheel Bearing Adjustment Procedure Models: 2001-2002 Chevrolet and GMC C/K and G-Van Models with 10.5 and 11.5 Inch Axles This bulletin is being issued to revise the Wheel Bearing Adjustment procedure in the Rear Drive Axle sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within Service Information (SI). If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Wheel Bearing Adjustment Preliminary Inspection Important: Ensure the brakes are fully released and do not drag. Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement. 3. Remove the hub adjuster nut retaining ring. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Drive Train - Revised Wheel Bearing Adjustment Procedure > Page 10606 4. Remove the adjuster nut lock key. Notice: Refer to Fastener Notice in Cautions and Notices. 5. Tighten the wheel bearing adjusting nut using the J 2222-C. Rotate the hub in the opposite direction to the way the adjuster nut is turning. Ensure the inner bearing and the seal seats against the spindle shoulder. Tighten Tighten the adjusting nut to 70 N.m (52 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Drive Train - Revised Wheel Bearing Adjustment Procedure > Page 10607 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. Important: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. 9. Install the retaining ring. 10. Install the axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement. 11. Inspect the lubricant level and add, if necessary. Refer to Lubricant Level Check. 12. Lower the vehicle. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Page 10608 Wheel Bearing: Service and Repair "For information regarding this component please refer to wheel hub service and repair" Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Shaft Nut ............................................................................................................................ ................................................ 210 Nm (155 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Service and Repair Wheel Seal: Service and Repair "For information regarding this component please refer to wheel hub service and repair" Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Tire/Wheel - Spare Tire Is Non-Matching To Other Tires Spare Tire: Technical Service Bulletins Tire/Wheel - Spare Tire Is Non-Matching To Other Tires INFORMATION Bulletin No.: 02-03-10-001E Date: November 01, 2010 Subject: Spare Tire is a Different Size than Other Tires Models: 2002-2011 Cadillac Escalade Models 1999-2007 Chevrolet Silverado (Classic) 2000-2011 Chevrolet Suburban, Tahoe 2002-2011 Chevrolet Avalanche 1999-2007 GMC Sierra (Classic) 2001 GMC Sierra C3 2001-2011 GMC Yukon Models 2002-2011 GMC Sierra Denali Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-03-10-001D (Section 03 - Suspension). This bulletin is being issued to supply additional information concerning the spare tire on the above vehicles. You or your customers may have noticed that the spare tire has a 16-inch diameter steel wheel or 17-inch diameter aluminum wheel while the road tires have a 17-inch, 18-inch, 20-inch or 22-inch diameter aluminum wheel. Although the spare tire has a different wheel diameter and may be a different brand, the rolling circumference is nearly identical to the road tires. The size difference will not cause a concern because the spare and the other tires will travel the same distance in one revolution. This combination of non-matching tires is used most often on full-size trucks. These vehicles use a road tire and wheel combination that may be too large to conveniently fit the storage compartment space of the vehicle. The customer may not be able to easily remove the spare tire/wheel from the storage area because of its size and/or weight. A steel spare wheel, rather than an aluminum one, may be used since the spare is stowed under the vehicle where it is exposed to road and weather elements. A steel wheel is less likely to incur cosmetic damage while in the stowed position for long periods of time. Please provide this information to your customers. Also, remind your customers of the importance of following the tire maintenance schedule as listed in their Owner Manual. Additional tire care information can be found by visiting www.gmtiresafety.com or contacting GM toll-free. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 10649 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 10650 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 10651 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 10656 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 10661 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 10662 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 10663 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration Wheels: Customer Interest Wheels/Tires - Slow Tire Leak/Vibration Bulletin No.: 03-03-10-001D Date: January 17, 2008 TECHNICAL Subject: Tire Slowly Goes Flat and/or Excessive wheel Vibration Caused By Bead Splits (Replace wheels with New Heavy Duty Rim Version) Models: 1999-2006 Chevrolet Silverado 1500 Series Pickup Models (Classic) 1999-2006 Chevrolet Express 1500 Series Vans 2000-2006 Chevrolet Suburban Tahoe 1999-2006 GMC Sierra 1500 Series Pickup Models (Classic) 1999-2006 GMC Savana 1500 Series Vans 2002-2006 GMC Yukon Yukon XL 2007 GMC Sierra Denali Crew Cab with 6-Bolt, 16 X 6.5 Full Face Steel wheel (Base and RPO PY2) Supercede: This bulletin is being revised to add the Express and Savana models and add information to the Correction section. Please discard Corporate Bulletin Number 03-03-10-001C (Section 03 Suspension). Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on a tire that slowly goes flat and/or excessive wheel vibration. This condition is more apparent on vehicles in which customer usage typically involves frequent severe conditions such as: High load (at or above gross vehicle weight) Rough road/off road usage Fleet/Commercial usage Cause The wheel may experience a crack or split in the outboard bead seat weld area. A weld attaches the rim and disc together on full-face wheels in this area. To identify this wheel it is offered in a silver painted version P/N 9593915 code "TZA" and a chrome-clad version, P/N 9593150 code "RSC" (these codes are stamped into the wheel's disc near the bolt holes). Correction Wheel replacement should only be done for air loss and/or vibration caused by bead splits. A new heavy-duty rim version of these wheels has been released for service. The new heavy-duty painted wheel is P/N 9595245 code "FFU" used as a road wheel and spare. The new heavy-duty chrome clad version is P/N 9595306 code "FFW" used as a road wheel only (these codes are stamped into the inboard rim flange balance weight area and are also on a sticker near the bolt holes). If a condition of a crack or split as described above occurs all (5) five of the original wheels on the vehicle should be replaced with the new heavy-duty wheels as follows: Replace road wheel P/N 9593915 with P/N 9595245. Replace road wheel PIN 9593150 with P/N 9595306. Replace the spare wheel with P/N 9595245 on all vehicles. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration > Page 10668 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 10674 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 10675 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 10676 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 10681 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 10686 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 10687 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 10692 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 10693 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 10694 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 10699 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 10704 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 10705 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 10706 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration Wheels: All Technical Service Bulletins Wheels/Tires - Slow Tire Leak/Vibration Bulletin No.: 03-03-10-001D Date: January 17, 2008 TECHNICAL Subject: Tire Slowly Goes Flat and/or Excessive wheel Vibration Caused By Bead Splits (Replace wheels with New Heavy Duty Rim Version) Models: 1999-2006 Chevrolet Silverado 1500 Series Pickup Models (Classic) 1999-2006 Chevrolet Express 1500 Series Vans 2000-2006 Chevrolet Suburban Tahoe 1999-2006 GMC Sierra 1500 Series Pickup Models (Classic) 1999-2006 GMC Savana 1500 Series Vans 2002-2006 GMC Yukon Yukon XL 2007 GMC Sierra Denali Crew Cab with 6-Bolt, 16 X 6.5 Full Face Steel wheel (Base and RPO PY2) Supercede: This bulletin is being revised to add the Express and Savana models and add information to the Correction section. Please discard Corporate Bulletin Number 03-03-10-001C (Section 03 Suspension). Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on a tire that slowly goes flat and/or excessive wheel vibration. This condition is more apparent on vehicles in which customer usage typically involves frequent severe conditions such as: High load (at or above gross vehicle weight) Rough road/off road usage Fleet/Commercial usage Cause The wheel may experience a crack or split in the outboard bead seat weld area. A weld attaches the rim and disc together on full-face wheels in this area. To identify this wheel it is offered in a silver painted version P/N 9593915 code "TZA" and a chrome-clad version, P/N 9593150 code "RSC" (these codes are stamped into the wheel's disc near the bolt holes). Correction Wheel replacement should only be done for air loss and/or vibration caused by bead splits. A new heavy-duty rim version of these wheels has been released for service. The new heavy-duty painted wheel is P/N 9595245 code "FFU" used as a road wheel and spare. The new heavy-duty chrome clad version is P/N 9595306 code "FFW" used as a road wheel only (these codes are stamped into the inboard rim flange balance weight area and are also on a sticker near the bolt holes). If a condition of a crack or split as described above occurs all (5) five of the original wheels on the vehicle should be replaced with the new heavy-duty wheels as follows: Replace road wheel P/N 9593915 with P/N 9595245. Replace road wheel PIN 9593150 with P/N 9595306. Replace the spare wheel with P/N 9595245 on all vehicles. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 03-03-10-001D > Jan > 08 > Wheels/Tires - Slow Tire Leak/Vibration > Page 10715 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 10721 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 10722 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 10723 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 10728 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 10733 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 10734 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 10739 Wheels: Testing and Inspection Wheel Mounting Surface Check Replace any wheels that are bent or dented, or have excessive lateral or radial runout. Wheels with runout greater than specified may cause objectionable vibrations. 1. Use a straight edge 203 - 229 mm (8 - 9 inch) long. Place the straight edge on the wheel inboard mounting surface. Try to rock the straightedge up and down within the mounting surface. 2. Repeat this procedure on at least 3-4 different positions on the inboard mounting surface. ^ The outer ring of the mounting surface normally is raised above everything inside the mounting surface. ^ The mounting surface will be raised above the outer ring if the wheel mounting surface has been bent on a tire changer. ^ If you can rock the straight edge, the mounting surface is bent and you must replace the wheel. 3. Inspect the mounting wheel/nut holes for damage caused from over-torquing the wheel/nuts. Inspect for collapsed wheel/nut bosses. Inspect for cracked wheel bosses. Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components ^ Adverse vehicle steering stability caused by the modified scrub radius Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 10740 ^ Damage to the vehicle caused by the modified ground clearance ^ Speedometer and odometer inaccuracy Important: ^ Replacement wheels must be equivalent to the original equipment wheels in the following ways: The load capacity - The wheel diameter - The rim width - The wheel offset - The mounting configuration ^ A wheel of the incorrect size or type may affect the following conditions: Wheel and hub-bearing life - Brake cooling - Speedometer/odometer calibration - Vehicle ground clearance - Tire clearance to the body and the chassis 4. Replace the wheel if the wheel is bent. 5. Replace the wheel if the wheel/nut boss area is cracked. Identify steel wheels with a 2 or 3-letter code stamped into the rim near the valve stem. Aluminum wheels have the code, the part number, and the manufacturer identification cast into the back side of the wheel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair Repair Instructions 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. Important: Do not damage the exterior surface of the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 8. Use general purpose cleaner such as EMS, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 10743 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing A protective clear coating covers the surface of original equipment cast aluminum wheels. A surface degradation may develop if frequent automatic car wash cleaning wears off the factory applied protective clear coating. This can happen at some automatic car wash facilities that use aggressive brushes to clean whitewalls and tires. Once you damage the protective clear coating, exposure to caustic cleaners and road salt can cause further surface deterioration. Damage to the protective clear coating is corrected by replacing the damaged wheel. Refinishing is no longer recommended. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 10744 Wheels: Service and Repair Tire and Wheel Removal and Installation Tire and Wheel Removal and Installation Tools Required ^ J39544-KIT Complete Torque Socket Set Caution: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident. Notice: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. Important: Removing wheels can be difficult because of foreign material or a tight fit between the wheel center hole and the hub or rotor. Excessive force, such as hammering on the wheel or tire, can cause damage. Slightly tapping the tire side wall with a rubber mallet is acceptable. 1. Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut two turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. Removal Procedure 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel nuts from the tire and wheel. 3. Mark the location of the tire and wheel to the hub assembly. 4. Remove the tire and wheel from the vehicle. 5. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 10745 Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. Notice: A torque wrench or J39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. 1. Install the tire and wheel. Align the locating mark of the tire and wheel to the hub. Notice: Refer to Fastener Notice in Service Precautions. Important: Tighten the nuts evenly and alternately in order to avoid excessive runout. 2. Install the wheel nuts. Tighten the wheel nuts as shown to 190 Nm (140 ft. lbs.). 3. Remove the safety stands. 4. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Drive Train - Revised Wheel Bearing Adjustment Procedure Wheel Bearing: Technical Service Bulletins Drive Train - Revised Wheel Bearing Adjustment Procedure File In Section: 04 - Driveline Axle Bulletin No.: 02-04-20-002 Date: May, 2002 SERVICE MANUAL UPDATE Subject: Revised Wheel Bearing Adjustment Procedure Models: 2001-2002 Chevrolet and GMC C/K and G-Van Models with 10.5 and 11.5 Inch Axles This bulletin is being issued to revise the Wheel Bearing Adjustment procedure in the Rear Drive Axle sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within Service Information (SI). If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Wheel Bearing Adjustment Preliminary Inspection Important: Ensure the brakes are fully released and do not drag. Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement. 3. Remove the hub adjuster nut retaining ring. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Drive Train - Revised Wheel Bearing Adjustment Procedure > Page 10750 4. Remove the adjuster nut lock key. Notice: Refer to Fastener Notice in Cautions and Notices. 5. Tighten the wheel bearing adjusting nut using the J 2222-C. Rotate the hub in the opposite direction to the way the adjuster nut is turning. Ensure the inner bearing and the seal seats against the spindle shoulder. Tighten Tighten the adjusting nut to 70 N.m (52 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Drive Train - Revised Wheel Bearing Adjustment Procedure > Page 10751 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. Important: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. 9. Install the retaining ring. 10. Install the axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement. 11. Inspect the lubricant level and add, if necessary. Refer to Lubricant Level Check. 12. Lower the vehicle. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 10752 Wheel Bearing: Service and Repair "For information regarding this component please refer to wheel hub service and repair" Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Wheels - Correct Hub Cap Installation Procedure Wheel Cover: Technical Service Bulletins Wheels - Correct Hub Cap Installation Procedure Bulletin No.: 03-03-10-002B Date: November 02, 2005 INFORMATION Subject: Use of Correct Installation Procedure for Loose Hubcap Assembly Models: 1998-2006 Chevrolet Express Van 1999-2006 Chevrolet Silverado Models 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1998-2006 GMC Savana Van 1999-2006 GMC Sierra Models 2000-2006 GMC Yukon, Yukon XL Models Supercede: This bulletin is being revised to add the 2006 model year. Please discard Corporate Bulletin Number 03-03-10-002A (Section 03 - Suspension). Some hubcap assemblies on the above-listed vehicles are being returned to the Warranty Parts Center (WPC) for loose and/or rattle conditions. Some returned hubcaps have the stand-off insulators removed. Analyses of these parts show no out of specification condition. Hubcap assemblies are placed in the vehicle by the assembly plant for dealer installation. Installation is done by threading the six or eight plastic nut caps, which are part of the hubcap assembly, to the external threads of the wheel (lug) nuts. If over-tightened, these plastic nut caps will jump threads, as designed, causing a loose or rattle condition. Important: ^ DO NOT over-tighten the plastic nut caps. ^ DO NOT use an impact wrench on the plastic nut caps. ^ DO NOT modify or remove the stand-off insulators from the plastic hubcap assembly. The nut cap system is designed to skip a thread if over-tightened. DO NOT replace the hubcap assembly if this happens. Hold hubcap (2) firmly in place on wheel with the plastic wheel nut caps (3) aligned with the steel wheel nuts (1). Hand snug each nut cap (3) (using a hand held deep socket or torque stick) until fully seated against the hubcap (2). You should feel the nut cap (3) ratchet against the hubcap (2) a couple times as the nut cap (3) seats. After all nut caps (3) have been seated, check tightness of each nut cap (3) using the socket or torque stick and tighten any nut cap (3) that may have loosened. If a nut cap (3) jumps thread (a design feature to prevent damage) and becomes loose during tightening, continue to tighten and stop short of thread jump. Follow the installation instruction sheet that is included in each hubcap package. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Wheels - Correct Hub Cap Installation Procedure > Page 10757 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Shaft Nut ............................................................................................................................ ................................................ 210 Nm (155 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 10770 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing > Page 10776 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Nut Torque Wheel Fastener: Specifications Wheel Nut Torque Single Wheel Nuts ............................................................................................................................... ................................................. 190 Nm (140 ft. lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Nut Torque > Page 10779 Lug Nut Torque Patterns Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Wheel Stud Replacement Tools Required ^ J43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the wheel stud from the hub flange using the J43631. 5. Remove the wheel stud from the hub flange. Installation Procedure 1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange. 4. Tighten the lug nut until the stud contacts the back of the hub flange. 5. Remove the wheel nut. 6. Remove the washers. 7. Install the brake rotor. 8. Install the tire and wheel. 9. Remove the safety stands. 10. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 10782 Wheel Fastener: Service and Repair Rear Wheel Stud Replacement Tools Required ^ J43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. 4. Remove the wheel stud from the axle flange using the J43631 for the 15 series. 5. Remove the axle shaft for vehicles with 9.5 inch ring gear. 6. Remove the rear hub assembly for vehicles with 10.5 in ring gear. 7. Remove the wheel stud from the axle flange using the J43631. 8. Remove the wheel stud from the hub flange using the J43631. Installation Procedure 1. Install the stud into the axle flange for the 15 Series. 2. Install the 4 washers and the lug nut to the stud. 3. Tighten the lug nut in order to draw the stud into the flange until the stud fully seats. 4. Remove the lug nut and the washers. 5. Install the axle shaft for the vehicles with 9.5 in ring gear. 6. Install the rear hub assembly for the vehicles with 10.5 in ring gear. 7. Install the rotor. 8. Install the tire and wheel. 9. Remove the safety stands. 10. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Service and Repair Wheel Seal: Service and Repair "For information regarding this component please refer to wheel hub service and repair" Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Locations > Page 10790 Accumulator HVAC: Service and Repair ACCUMULATOR REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Disconnect the electrical connector from the A/C low pressure switch. 3. Remove the compressor hose nut from the accumulator. 4. Disconnect the compressor hose from the accumulator. 5. Remove the nut (2) from the evaporator fitting. 6. Remove the accumulator bracket nut (4) from the retaining stud. 7. Remove the accumulator (3). 8. Remove the retaining bracket bolt (5). 9. Remove the retaining bracket (6) from the accumulator. 10. Remove the O-ring seals. INSTALLATION PROCEDURE 1. Install new O-ring seals. 2. Install the retaining bracket (6) to the accumulator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Locations > Page 10791 NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retaining bracket bolt (5). Tighten Tighten the accumulator bracket bolt to 10 N.m (89 lb in). 4. Install the accumulator (3). 5. Install the accumulator bracket nut (4). Tighten Tighten the accumulator bracket nut to 9 N.m (80 lb in). 6. Install the nut (2) to the evaporator fitting. Tighten Tighten the nut to 16 N.m (12 lb ft). 7. Connect the compressor hose to the accumulator. 8. Install the compressor hose nut to the accumulator. Tighten Tighten the compressor hose nut to 16 N.m (12 lb ft). 9. Connect the electrical connector to the A/C low pressure switch. 10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 11. Leak test the fittings of the component using the J 39400-A. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations Air Door Actuator / Motor: Component Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 10797 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 10798 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 10799 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 10800 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 10801 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 10802 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 10803 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 10804 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 10805 Air Door Actuator / Motor: Connector Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 10806 Locations View (Auxiliary HVAC Module) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 10807 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC System - Automatic Air Door Actuator / Motor: Diagrams HVAC System - Automatic Mode Actuator - Auxiliary (Manual Air Delivery) Air Temperature Actuator Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 10810 Air Temperature Actuator - Auxiliary (Manual Air Delivery) Mode Actuator Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 10811 Mode Actuator - Auxiliary Recirculation Actuator Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 10812 Air Door Actuator / Motor: Diagrams HVAC Systems - Manual Air Temperature Actuator - Auxiliary Recirculation Actuator Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 10813 Air Temperature Actuator Mode Actuator Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 10814 Mode Actuator - Auxiliary Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic Air Door Actuator / Motor: Service and Repair HVAC System - Automatic Air Temperature Actuator Replacement REMOVAL PROCEDURE 1. Remove the IP insulator. 2. Disconnect the electrical connector (8) from the air temperature actuator (9). 3. Remove the air temperature actuator retaining screws. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10817 4. Remove the air temperature actuator. INSTALLATION PROCEDURE 1. Install the air temperature actuator. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10818 2. Install the air temperature actuator retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector (8) to the air temperature actuator (9). 4. Install the IP insulator. Air Temperature Actuator Replacement - Auxiliary REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Disconnect the electrical connector from the air temperature actuator. 3. Remove the retaining screws from the air temperature actuator. 4. Remove the air temperature actuator (1) from the rear HVAC module. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10819 1. Install the air temperature actuator (1) to the rear HVAC module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the air temperature actuator retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector to the air temperature actuator. 4. Install the right rear quarter trim panel. Mode Actuator Replacement REMOVAL PROCEDURE 1. Remove the floor air outlet duct extension (1) from the floor duct (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10820 2. Disconnect the electrical connection at the mode actuator (10). 3. Remove the mode actuator mounting screws from the HVAC module. 4. Remove the mode actuator as an assembly with the actuator cam. INSTALLATION PROCEDURE 1. Install the mode actuator as an assembly with the actuator cam. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10821 - Line up the heater/defroster lever with the mode actuator cam slot. - Line up the A/C lever with the mode actuator cam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the mode actuator mounting screw to the HVAC module. Tighten Tighten the screw to 1.6 N.m (14 lb in). 3. Connect the electrical connection at the mode actuator (10). 4. Install the floor air outlet duct extension (1) to the floor air duct (2). Mode Actuator Replacement - Auxiliary REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10822 1. Remove the right rear quarter trim panel. 2. Disconnect the electrical connector from the mode actuator (1). 3. Remove the retaining screws from the mode actuator. 4. Remove the mode actuator (1) from the vehicle. INSTALLATION PROCEDURE 1. Install the mode actuator (1) to the vehicle. 2. Install the retaining screws to the mode actuator (1). 3. Connect the electrical connector to the mode actuator. 4. Install the left rear quarter trim panel. 5. Calibrate the HVAC module actuators. Refer to Re-Calibrating Actuators in HVAC Systems Automatic. Recirculation Actuator Replacement (RPO (CR2)) REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10823 1. Remove the instrument panel (IP) upper trim panel. Refer to IP Carrier Replacement in Instrument Panel, Gauges and Console. 2. Remove the IP lower trim panel and the glove box assembly. 3. Remove the passenger side air bag. Refer to Inflatable Restraint Instrument Panel Module Replacement in Restraint Systems. 4. Disconnect the electrical connection from the recirculation actuator (1). 5. Remove the recirculation actuator retaining screws. 6. Remove the recirculation actuator. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10824 1. Install the recirculation actuator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the recirculation actuator retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector to the recirculation actuator (1). 4. Install the passenger side air bag. Refer to Inflatable Restraint Instrument Panel Module Replacement in Restraint Systems. 5. Install the IP lower trim panel and the glove box assembly. 6. Install the IP upper trim panel. Refer to IP Carrier Replacement in Instrument Panel, Gauges and Console. 7. Calibrate the HVAC module actuators. Refer to Re-Calibrating Actuators. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10825 Air Door Actuator / Motor: Service and Repair HVAC System - Manual Air Temperature Actuator Replacement REMOVAL PROCEDURE 1. Remove the instrument panel hush panel. 2. Disconnect the electrical connector (8) from the air temperature actuator (9). 3. Remove the air temperature actuator retaining screws. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10826 4. Remove the air temperature actuator. INSTALLATION PROCEDURE 1. Install the air temperature actuator. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10827 2. Install the air temperature actuator retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector (8) to the air temperature actuator (9). 4. Install the instrument panel hush panel. 5. Calibrate the HVAC module actuators. Refer to Re-Calibrating Actuators in HVAC Systems - Automatic. Air Temperature Actuator Replacement - Auxiliary REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10828 1. Remove the right rear quarter trim panel. 2. Disconnect the electrical connector from the mode actuator (1). 3. Remove the retaining screws from the mode actuator. 4. Remove the mode actuator (1) from the vehicle. INSTALLATION PROCEDURE 1. Install the mode actuator (1) to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the mode actuator (1). Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector to the mode actuator. 4. Install the left rear quarter trim panel. Mode Actuator Replacement (Delphi) REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10829 1. Remove the floor air outlet duct extension (1) from the floor duct (2). 2. Disconnect the electrical connection at the mode actuator (10). 3. Remove the mode actuator mounting screws from the HVAC module. 4. Remove the mode actuator as an assembly with the actuator cam. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10830 INSTALLATION PROCEDURE 1. Install the mode actuator as an assembly with the actuator cam. - Line up the heater/defroster valve lever with the mode actuator cam slot. - Line up the A/C valve lever with the mode actuator cam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the mode actuator mounting screw to the HVAC module. Tighten Tighten the mode actuator mounting screw to 1.6 N.m (14 lb in). 3. Connect the electrical connection at the mode actuator (10). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10831 4. Install the floor air outlet duct extension (1) to the floor air duct (2). 5. Calibrate the HVAC module actuators. Refer to Re-Calibrating Actuators in HVAC Systems - Automatic. Mode Actuator Replacement - Auxiliary REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Disconnect the electrical connector from the mode actuator (1). 3. Remove the retaining screws from the mode actuator. 4. Remove the mode actuator (1) from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10832 1. Install the mode actuator (1) to the vehicle. 2. Install the retaining screws to the mode actuator (1). 3. Connect the electrical connector to the mode actuator. 4. Install the left rear quarter trim panel. 5. Calibrate the HVAC module actuators. Refer to Re-Calibrating Actuators in HVAC Systems - Automatic. Recirculation Actuator Replacement (Delphi) REMOVAL PROCEDURE 1. Remove the instrument panel (IP) upper trim panel. Refer to IP Carrier Replacement in Instrument Panel, Gauges and Console. 2. Remove the IP lower trim panel and the glove box assembly. 3. Remove the passenger side air bag. Refer to Inflatable Restraint Instrument Panel Module Replacement in Restraint Systems. 4. Disconnect the electrical connection from the recirculation actuator (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10833 5. Remove the recirculation actuator retaining screws 6. Remove the recirculation actuator. INSTALLATION PROCEDURE 1. Install the recirculation actuator. NOTE: Refer to Fastener Notice in Service Precautions. 2. install the recirculation actuator retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 10834 3. Connect the electrical connector to the recirculation actuator (1). 4. Install the passenger side air bag. Refer to Inflatable Restraint Instrument Panel Module Replacement in Restraint Systems. 5. Install the IP lower trim panel and the glove box assembly. 6. Install the IP upper trim panel. Refer to IP Carrier Replacement in Instrument Panel, Gauges and Console. 7. Inspect the system for proper operation. 8. Calibrate the HVAC module actuators. Refer to Re-Calibrating Actuators in HVAC Systems - Automatic. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Locations > HVAC System - Manual Air Duct: Locations HVAC System - Manual Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Locations > HVAC System - Manual > Page 10839 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Locations > HVAC System - Manual > Page 10840 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Locations > HVAC System - Manual > Page 10841 Air Duct: Locations HVAC System - Automatic Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Locations > HVAC System - Manual > Page 10842 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Ducts Replacement - Auxiliary (Lower) Air Duct: Service and Repair Air Distribution Ducts Replacement - Auxiliary (Lower) REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Remove the air temperature sensor if equipped 3. Remove the lower air duct fastener. 4. Remove the lower air duct (5) from the vehicle. INSTALLATION PROCEDURE 1. Install the air duct (5) to the vehicle. 2. Install the lower air duct fastener. 3. Install the air temperature sensor if equipped 4. Install the left rear quarter trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Ducts Replacement - Auxiliary (Lower) > Page 10845 Air Duct: Service and Repair Air Distribution Ducts Replacement - Auxiliary (Upper) REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Remove the upper air temperature sensor if equipped. 3. Remove the upper air duct fastener (5). 4. Remove the duct (6) from the vehicle. INSTALLATION PROCEDURE 1. Install the duct (6) to the vehicle. 2. Install the upper air duct fastener (5). 3. Install the upper air temperature sensor if equipped 4. Install the right rear quarter trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Ducts Replacement - Auxiliary (Lower) > Page 10846 Air Duct: Service and Repair Air Distributor Duct Replacement REMOVAL PROCEDURE 1. Remove the IP. Refer to IP Carrier Replacement in Instrument Panel, Gages and Console. 2. Remove the air distribution duct retaining screws. 3. Remove the air distribution duct. INSTALLATION PROCEDURE 1. Install the air distribution duct. 2. Install the air distribution duct retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 4. Install the IP. Refer to IP Carrier Replacement in Instrument Panel, Gages and Console. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Ducts Replacement - Auxiliary (Lower) > Page 10847 Air Duct: Service and Repair Deflector Replacement - Auxiliary A/C Outlet - Headliner REMOVAL PROCEDURE 1. Turn the air deflector louver counter clockwise in order to release it from the headliner. 2. Remove the air deflector louver from the vehicle. INSTALLATION PROCEDURE 1. Align the air deflector louver into the opening in the headliner. 2. Turn the air deflector louver clockwise in order to retain it to the headliner. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Side Window Air Register: Service and Repair Air Outlet Replacement - Side Window REMOVAL PROCEDURE 1. Remove the IP. Refer to IP Carrier Replacement in Instrument Panel, Gages and Console. 2. Remove the air tube from the side window outlet duct. 3. Remove the side window air outlet duct. INSTALLATION PROCEDURE 1. Install the side window air outlet duct. 2. Install the air tube to the side window outlet duct. 3. Install the IP. Refer to IP Carrier Replacement in Instrument Panel, Gages and Console. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Side Window > Page 10853 Air Register: Service and Repair Air Outlet Replacement - Floor REMOVAL PROCEDURE 1. Remove the heater/ventilation module. Refer to Heater Core Replacement. 2. Remove the floor air outlet screws. 3. Remove the floor air outlet (1). INSTALLATION PROCEDURE 1. Install the floor air outlet. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the floor air outlet screws (1). Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Install the heater/ventilation module. Refer to Heater Core Replacement. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Side Window > Page 10854 Air Register: Service and Repair Air Outlet Replacement - Rear Floor REMOVAL PROCEDURE 1. Remove the floor console. 2. Remove the seats. 3. Remove the HVAC module. Refer to Heater Core Replacement. 4. Roll the carpeting back to expose the rear floor air ducts. 5. Remove the rear floor ducts from the floor studs. 6. Remove the rear floor duct. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Side Window > Page 10855 1. Install the rear floor air duct. 2. Install the rear floor ducts from the floor studs. 3. Position the carpeting back into place. 4. Install the HVAC module. Refer to Heater Core Replacement 5. Install the seats. 6. Install the floor console. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper Air Temperature Sensor - Upper Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper > Page 10861 Air Temperature Sensor - Lower Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper > Page 10862 Air Temperature Sensor - Ambient Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper > Page 10863 Air Temperature Sensor - Lower Auxiliary Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper > Page 10864 Air Temperature Sensor Assembly - Inside (Over Head) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 10865 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL PROCEDURE 1. Remove the Park/Turn Signal. 2. Disconnect the electrical connector from the ambient air temperature sensor (3). 3. Remove the ambient air temperature sensor (3). INSTALLATION PROCEDURE 1. Install the ambient air temperature sensor (3). 2. Connect the electrical connector to the ambient air temperature sensor (3). 3. Install the Park/Turn Signal. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Blower Motor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10871 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10872 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10873 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10874 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10875 Auxiliary Blower Motor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10876 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10877 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10878 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10879 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10880 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10881 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10882 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10883 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10884 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10885 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10886 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10887 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10888 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10889 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10890 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10891 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10892 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10893 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10894 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10895 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10896 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10897 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10898 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10899 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10900 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Component Locations Blower Motor Resistor: Component Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Component Locations > Page 10908 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Component Locations > Page 10909 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Component Locations > Page 10910 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Component Locations > Page 10911 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Component Locations > Page 10912 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > HVAC Systems - Manual Blower Motor Resistor: Diagrams HVAC Systems - Manual Blower Motor Resistor Assembly Blower Motor Resistor Assembly - Auxiliary - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > HVAC Systems - Manual > Page 10915 Blower Motor Resistor Assembly - Auxiliary - C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > HVAC Systems - Manual > Page 10916 Blower Motor Resistor: Diagrams HVAC Systems - Automatic Blower Motor Resistor Assembly - Auxiliary - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > HVAC Systems - Manual > Page 10917 HVAC Control Module - Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Replacement Blower Motor Resistor: Service and Repair Blower Motor Resistor Replacement REMOVAL PROCEDURE 1. If equipped, remove the IP sound insulator. 2. Disconnect the electrical connection from the blower motor. 3. Disconnect the electrical connection from the blower motor resistor. 4. Remove the blower motor resistor retaining screws. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Replacement > Page 10920 5. Remove the blower motor resistor. INSTALLATION PROCEDURE 1. Install the blower motor resistor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor resistor retaining screws. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Replacement > Page 10921 Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connection to the blower motor resistor. 4. Connect the electrical connection to the blower motor. 5. If equipped, install the IP sound insulator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Replacement > Page 10922 Blower Motor Resistor: Service and Repair Blower Motor Resistor Replacement - Auxiliary REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Disconnect the electrical connector from the blower motor resistor. 3. Remove the retaining screws from the blower motor resistor. 4. Remove the blower motor resistor (1) from the vehicle. INSTALLATION PROCEDURE 1. Install the blower motor resistor (1) to the vehicle. 2. Install the retaining screws to the blower motor resistor. 3. Connect the electrical connector to the blower motor resistor. 4. Install the right rear quarter trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams HVAC Blower Motor Control Switch - C2 (Part Of HVAC Control Assembly) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Page 10926 Blower Motor Switch: Service and Repair BLOWER MOTOR SWITCH REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Separate the front of the console (1) from the headliner. 2. Remove the blower motor switch (2) by releasing the tabs at the rear of the switch housing. 3. Disconnect the electrical connector (3). INSTALLATION PROCEDURE 1. Connect the electrical connector (3). 2. Install the blower motor switch (2) to the switch housing. 3. Install the console (1) to the headliner. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations > Page 10930 Cabin Air Filter: Service and Repair REMOVAL PROCEDURE 1. If equipped, remove the Instrument Panel (I/P) sound insulator. 2. Remove the filter access door screw. 3. Remove the filter access door (1) from the HVAC module. 4. Remove the passenger compartment air filter (2). INSTALLATION PROCEDURE 1. Install the passenger compartment air filter (2). 2. Install the filter access door (1) to the HVAC module. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the filter access door screw. Tighten Tighten The Screw to 1.6 Nm (14 lb in). 4. If equipped, install the I/P sound insulator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair Cabin Temperature Sensor / Switch: Service and Repair INSIDE AIR TEMPERATURE SENSOR REPLACEMENT (OVERHEAD) REMOVAL PROCEDURE 1. Remove the left windshield garnish molding. 2. Remove the left center pillar assist handle. 3. Remove the left center pillar garnish molding. 4. Remove the left sunshade. 5. Remove the retaining screws from the headliner. 6. Gently pull down the headliner. 7. Remove the inside air temperature sensor from the headliner. 8. Disconnect the electrical connector from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Page 10934 1. Install the inside air temperature sensor to the headliner. 2. Connect the electrical connector to the inside air temperature sensor. 3. Install the screws to the headliner. 4. Install the left sunshade. 5. Install the left center pillar garnish molding. 6. Install the left center assist handle. 7. Install the left windshield garnish molding. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Service and Repair > Pressure Relief Valve Replacement Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement REMOVAL PROCEDURE 1. Open the lift gate. 2. Remove the outer quarter panel upper applique. 3. Remove the upper rear garnish molding. 4. Remove the corner rear garnish molding. 5. Depress the locking tab on the back of the pressure relief valve to remove from the rear of the vehicle. 6. Remove the pressure relief valve from the vehicle. INSTALLATION PROCEDURE 1. Install the pressure relief valve. 2. Press the pressure relief valve to fully seat. 3. Install the upper rear garnish molding. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Service and Repair > Pressure Relief Valve Replacement > Page 10939 4. Install the outer quarter panel upper applique. 5. Close the lift gate Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Service and Repair > Pressure Relief Valve Replacement > Page 10940 Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement (Utility) Pressure Relief Valve Replacement (Utility) Removal Procedure 1. Open the lift gate. 2. Remove the outer quarter panel upper applique. 3. Remove the upper rear garnish molding. 4. Remove the corner rear garnish molding. 5. Depress the locking tab on the back of the pressure relief valve to remove from the rear of the vehicle. 6. Remove the pressure relief valve from the vehicle. Installation Procedure 1. Install the pressure relief valve. 2. Press the pressure relief valve to fully seat. 3. Install the upper rear garnish molding. 4. Install the outer quarter panel upper applique. 5. Close the lift gate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement (Utility) Removal Procedure 1. Open the lift gate. 2. Remove the outer quarter panel upper applique. 3. Remove the upper rear garnish molding. 4. Remove the corner rear garnish molding. 5. Depress the locking tab on the back of the pressure relief valve to remove from the rear of the vehicle. 6. Remove the pressure relief valve from the vehicle. Installation Procedure 1. Install the pressure relief valve. 2. Press the pressure relief valve to fully seat. 3. Install the upper rear garnish molding. 4. Install the outer quarter panel upper applique. 5. Close the lift gate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Compressor Clutch Gap....................0.50 - 0.76 mm Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Component Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Component Locations > Page 10950 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > HVAC systems - Manual A/C Compressor Clutch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > HVAC systems - Manual > Page 10953 A/C Compressor Clutch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 10954 Compressor Clutch: Service Precautions CAUTION: Use care in order to prevent personal injury when striking the staking pin with a hammer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > With Harrison Compressor Compressor Clutch: Service and Repair With Harrison Compressor Clutch Rotor and/or Bearing Install (HT6/HD6/HU6) TOOLS REQUIRED - J 6083 External Snap Ring Pliers - J 33023-A Puller Pilot - J 41552 Compressor Pulley Puller - J 29886 Driver Handle - J 21352-A Support Block - J 9481-A Bearing Installer - J 33019 Bearing Staking Tool - J 33017 Pulley and Bearing Assembly Installer - J 8433-1 Puller Bar - J 8433-3 Forcing Screw - J 34992 Compressor Holding Fixture NOTE: Do not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face will be bent. 1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during bearing installation. 2. Use the following tools in order to align the new bearing squarely with the hub bore: - The J 41552 - The J 9481-A - The J 29886 3. Drive the bearing fully into the hub. The installer will apply force to the outer race of the bearing, if used as shown. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > With Harrison Compressor > Page 10957 4. Place the J 33019 in the hub bore. 5. Shift the rotor and bearing assembly on the J21352-A in order to fully support the hub under the staking pin location. Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide. Properly position the stake pin in the guide after each impact on the pin. CAUTION: Use care in order to prevent personal injury when striking the staking pin with a hammer. 6. Strike the staking pin with a hammer until a metal stake, similar to the original, forms down to but not touching the bearing. IMPORTANT: Noisy bearing operation and reduced bearing life may result if the outer bearing race is deformed while staking. Ensure that the stake metal does not contact the outer race of the bearing. 7. Stake 3 locations on the bearing race 120 degrees apart as shown. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > With Harrison Compressor > Page 10958 8. With the compressor mounted on the J 34992, position the pulley rotor (1) and the bearing assembly on the front head. 9. Position the d 33017 and the J 33023-A directly over the inner race of the bearing. 10. Position the J 8433-1 on the J 33023-A. 11. Assemble the 2 through bolts and the washers through the puller bar slots. 12. Thread the through bolts into the J 34992. Ensure that the thread of the through bolts engage the full thickness of the J 34992. 13. Tighten the center screw in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the compressor front head. If the J33017 slips off direct in-line contact with the inner race of the bearing, perform the following steps: 13.1. Loosen the J8433-3. 13.2. Realign the installer and the pilot in order to ensure that the J 33017 properly clears the front head. 14. Use the J 6083 in order to install the following components: 15. The pulley rotor (1) 16. The retaining ring (2) 17. Install the clutch plate and hub assembly. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Clutch Rotor and/or Bearing Removal (HT6/HD6/HU6) TOOLS REQUIRED - J 6083 External Snap Ring Pliers - J 33023-A Puller Pilot - J 41552 Compressor Pulley Puller - J 29886 Driver Handle - J 9398-A Bearing Remover Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > With Harrison Compressor > Page 10959 1. Remove the clutch plate and hub assembly. 2. Use the J 6083 in order to remove the following components: - The pulley rotor (1) - The bearing assembly retaining ring (2) 3. Install the J 33023-A to the front head. 4. Install the J 41552 down into the inner circle of slots (1) in the rotor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > With Harrison Compressor > Page 10960 5. Turn the J 41552 clockwise in the slots in the rotor. 6. Perform the following steps in order to remove the pulley rotor and bearing assembly: 6.1. Hold the J 41552 in position. 6.2. Tighten the puller screw against the puller guide. 6.3. Remove the pulley rotor and bearing assembly. 7. Use the following procedure in order to properly support the rotor hub during bearing removal in order to prevent pulley rotor damage: 7.1. Remove the forcing screw from the J 41552. 7.2. Ensure that the puller tangs still engage in the rotor slots. 7.3. Invert the assembly onto a solid flat surface or blocks. NOTE: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged. 8. Use the J 9398-A and the J29886 in order to drive the bearing out of the rotor hub. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Compressor Clutch Plate/Hub Assembly Replacement (HT6/HD6/HU6) TOOLS REQUIRED - J 34992 Compressor Holding Fixture - J 33013-B Hub and Drive Plate Remover/Installer REMOVAL PROCEDURE 1. Remove the A/C compressor. 2. Clamp the J 34992 in a vise. 3. Use thumb screws in order to attach the compressor to the holding fixture. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > With Harrison Compressor > Page 10961 NOTE: Do not drive or pound on the clutch hub or shaft. Internal damage to the compressor may result. The forcing tip on the J 33013-B remover/installer center screw must be flat or the end of the shaft/axial plate assembly will be damaged. 4. Ensure that the center screw forces the tip to thrust against the end of the shaft. 5. Thread the J 33013-B into the hub. 6. While holding the body of J 33013-B of the remover with a wrench, turn the center screw into the remover body in order to remove the clutch plate and hub assembly (1). 7. Remove the shaft key. Retain the shaft key for reassembly. INSTALLATION PROCEDURE 1. Install the shaft key (4) into the hub key groove. Allow the key to project approximately 3.2 mm (0.125 in) out of the keyway (3). The shaft key curves slightly in order to provide an interference fit in the hub key groove. 2. Clean the following components: - The clutch plate - The clutch rotor (2) 3. Align the shaft key (4) with the shaft keyway (3). 4. Place the clutch plate and the hub assembly (1) Onto the compressor shaft. 5. Remove the forcing tip on the J 33013-B. 6. Reverse the body direction on the center screw. 7. Install the J 33013-B with the bearing. 8. Back off the body of the J 33013-B as necessary in order to permit the center screw to be threaded onto the end of the compressor shaft. 9. Hold the center screw with a wrench. 10. Tighten the hex portion of the J 33013-B body in order to press the hub onto the shaft. 11. Tighten the body several turns. 12. Remove the installer. Ensure that the shaft key remains in place in the keyway. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > With Harrison Compressor > Page 10962 13. Install the clutch plate and hub assembly to the final position. Ensure that the air gap (2) between frictional surfaces of the clutch plate and clutch rotor measures within 0.50-0.76 mm (0.020-0.030 in). 14. Remove the J 33013-B. 15. Verify proper positioning of the shaft key. Ensure that the shaft key is even with or slightly above the clutch hub. 16. Spin the pulley rotor by hand in order to verify that the rotor does not rub against the clutch drive plate. 17. Install the A/C compressor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > With Harrison Compressor > Page 10963 Compressor Clutch: Service and Repair With Denso Compressor VEHICLES WITH DENSO COMPRESSOR The OE service manual does not provide service and repair information for the Denso A/C Compressor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal Compressor Clutch Coil: Service and Repair Compressor Clutch Coil Removal 1. Remove the clutch plate retaining bolt (1). 2. Remove the clutch plate assembly. 3. Remove the clutch hub/bearing snap ring. 4. Remove the clutch hub/bearing assembly. 5. Remove the clutch coil connector bracket retaining screw. 6. Remove the clutch coil snap ring. 7. Remove the clutch coil assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 10968 Compressor Clutch Coil: Service and Repair Compressor Clutch Coil Install 1. Install the coil assembly to the compressor. 2. Install the coil snap ring. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the coil connector retaining bracket screw. Tighten Tighten the screw to 9 N.m (80 lb in). 4. Install the clutch hub/bearing assembly. 5. Install the clutch hub/bearing snap ring. 6. Install the clutch plate assembly. 7. Install the clutch plate retaining bolt (1). Tighten Tighten the bolt to 18 N.m (13 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair Compressor Clutch Hub: Service and Repair TOOLS REQUIRED - J 34992 Compressor Holding Fixture - J 33013-B Hub and Drive Plate Remover/Installer REMOVAL PROCEDURE 1. Remove the A/C compressor. 2. Clamp the J 34992 in a vise. 3. Use thumb screws in order to attach the compressor to the holding fixture. NOTE: Do not drive or pound on the clutch hub or shaft. Internal damage to the compressor may result. The forcing tip on the J 33013-B remover/installer center screw must be flat or the end of the shaft/axial plate assembly will be damaged. 4. Ensure that the center screw forces the tip to thrust against the end of the shaft. 5. Thread the J 33013-B into the hub. 6. While holding the body of J 33013-B of the remover with a wrench, turn the center screw into the remover body in order to remove the clutch plate and hub assembly (1). 7. Remove the shaft key. Retain the shaft key for reassembly. INSTALLATION PROCEDURE 1. Install the shaft key (4) into the hub key groove. Allow the key to project approximately 3.2 mm (0.125 in) out of the keyway (3). The shaft key curves slightly in order to provide an interference fit in the hub key groove. 2. Clean the following components: - The clutch plate - The clutch rotor (2) 3. Align the shaft key (4) with the shaft keyway (3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > Page 10972 4. Place the clutch plate and the hub assembly (1) Onto the compressor shaft. 5. Remove the forcing tip on the J 33013-B. 6. Reverse the body direction on the center screw. 7. Install the J 33013-B with the bearing. 8. Back off the body of the J 33013-B as necessary in order to permit the center screw to be threaded onto the end of the compressor shaft. 9. Hold the center screw with a wrench. 10. Tighten the hex portion of the J 33013-B body in order to press the hub onto the shaft. 11. Tighten the body several turns. 12. Remove the installer. Ensure that the shaft key remains in place in the keyway. 13. Install the clutch plate and hub assembly to the final position. Ensure that the air gap (2) between frictional surfaces of the clutch plate and clutch rotor measures within 0.50-0.76 mm (0.020-0.030 in). 14. Remove the J 33013-B. 15. Verify proper positioning of the shaft key. Ensure that the shaft key is even with or slightly above the clutch hub. 16. Spin the pulley rotor by hand in order to verify that the rotor does not rub against the clutch drive plate. 17. Install the A/C compressor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 10976 Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover from the underhood convenience center (1). 2. Remove the compressor relay (2). INSTALLATION PROCEDURE 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair Condenser HVAC: Service and Repair CONDENSER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Disconnect the electrical connector from the air inlet duct. 3. Remove the PCV hose from the air cleaner. 4. Remove the air inlet assembly. 5. Reposition the upper radiator hose clamp from the radiator. 6. Remove the upper radiator hose. 7. Remove the upper fan shroud. 8. Reposition the lower radiator hose clamp from the radiator. 9. Remove the lower radiator hose. 10. Position the lower fan shroud to one side to allow removal of radiator. 11. Remove the radiator. 12. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 13. Remove the compressor discharge hose assembly bolt from the condenser. 14. Disconnect the compressor discharge hose assembly from the condenser. 15. Remove the evaporator tube nut from the condenser. 16. Disconnect the evaporator tube from the condenser. 17. Remove the. Insulator retainer bolts and the upper insulator retainers. 18. Remove the condenser from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 10980 1. Install the condenser to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the upper insulator retainers and the insulator retainer bolts. Tighten Tighten the bolts to 2.4 N.m (21 lb in). 3. Connect the evaporator tube to the condenser using new sealing washers. 4. Install the evaporator tube nut to the condenser. Tighten Tighten the evaporator tube nut to 16 N.m (12 lb ft). 5. Connect the compressor discharge hose to the condenser using new sealing washers. 6. Install the compressor discharge hose nut to the condenser Tighten Tighten the compressor discharge hose nut to 16 N.m (21 lb ft). 7. Install the radiator. 8. Install the lower radiator hose to the radiator. 9. Install the lower radiator clamp. 10. Install the upper fan shroud. 11. Install the upper radiator hose to the radiator. 12. Install the upper radiator clamp. 13. Install the air inlet assembly. 14. Connect the PCV hose to the air cleaner. 15. Connect the electrical connector to the air inlet duct. 16. Refill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 17. Evacuate and recharge the system. 18. Leak test the fittings of the component using the J 39400-A. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 01-01-39-007 > Jan > 02 > A/C - Loss of Mode/Temperature Control Control Assembly: Customer Interest A/C - Loss of Mode/Temperature Control File In Section: 01 - HVAC Bulletin No.: 01-01-39-007 Date: January, 2002 TECHNICAL Subject: Loss Of HVAC System Mode and/or Temperature Control (Reroute Wiring Harness) Models: 1999-2002 Chevrolet and GMC C/K Pickup Models (Silverado and Sierra) 1999-2002 Chevrolet and GMC C/K Utility Models (Avalanche, Suburban, Tahoe, Yukon, Yukon XL, Denali) 2001 GMC Sierra C3 2002 GMC Sierra Denali 2002 Cadillac Escalade, Escalade EXT Condition Some customers may comment that they cannot control the HVAC system modes and/or the temperature. These concerns may be intermittent. Cause There may be poor terminal contact and/or bent terminals in connectors C206 (RPO C68 automatic HVAC controls) or C296 (RPO C60 manual HVAC controls). Excessive tension on the wires due to the wiring harness being misrouted in the instrument panel carrier may cause these conditions. Correction 1. Remove the Air Bag fuse. 2. Disconnect the steering wheel and instrument panel (IP) air bag connectors. Refer to the SIR subsection of the Restraints section of the Service Manual for connector locations. 3. Remove the IP upper trim pad. 4. Locate connector C206 (6 cavities) or C296 (8 cavities). The connector is attached to a metal brace on the far right side of the IP carrier above the IP air distributor duct. 5. Inspect the routing of the wiring harness to the connector. The proper routing of the wiring harness is above the air distributor duct with no tension on the terminals in the connector. The routing is improper if the wiring harness is below the air distributor duct with excessive tension on the terminals in the connector. The excessive tension may cause poor terminal contact, resulting in open circuits, in the connector. The wires may also pull the terminals out of the connector or pull out of the terminal itself. 6. If the harness is routed properly, contact Technical Assistance for further information. 7. If the harness is misrouted, remove the connector from the brace. 8. Disconnect the connector. 9. Perform a pin drag test on the female terminals. 10. Inspect the male terminals for straightness. 11. Inspect the wire to terminal connection to insure that no wires have pulled out of the terminals. 12. Reroute the wiring harness above the air distributor duct. 13. Firmly reconnect and reseat the connector. 14. Reattach the connector to the metal brace. 15. Reinstall the IP upper trim pad. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 01-01-39-007 > Jan > 02 > A/C - Loss of Mode/Temperature Control > Page 10989 16. Turn Off the ignition and reconnect the steering wheel and IP air bags. 17. Reinstall the Air Bag fuse. 18. Turn ON the ignition and verify that the air bag light flashes seven times and goes out. 19. Clear any diagnostic trouble codes that may have been set. 20. Verify proper operation of the HVAC system mode and temperature controls. Warranty Information For vehicles repaired under warranty. use the table as shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 04-01-37-001 > Jan > 04 > A/C Control Knob Replacement Availability Control Assembly: All Technical Service Bulletins A/C - Control Knob Replacement Availability Bulletin No.: 04-01-37-001 Date: January 06, 2004 INFORMATION Subject: HVAC Control Knob Replacement Models: 2000-2004 All Passenger Cars and Light Duty Trucks 2003-04 HUMMER H2 HVAC Control Knob Availability Important: If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. The various knobs used on the HVAC controls of most GM vehicles are available for purchase separately from the HVAC head units. If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. Please use only the labor operation code listed below when replacing an HVAC control knob. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 01-01-39-007 > Jan > 02 > A/C - Loss of Mode/Temperature Control Control Assembly: All Technical Service Bulletins A/C - Loss of Mode/Temperature Control File In Section: 01 - HVAC Bulletin No.: 01-01-39-007 Date: January, 2002 TECHNICAL Subject: Loss Of HVAC System Mode and/or Temperature Control (Reroute Wiring Harness) Models: 1999-2002 Chevrolet and GMC C/K Pickup Models (Silverado and Sierra) 1999-2002 Chevrolet and GMC C/K Utility Models (Avalanche, Suburban, Tahoe, Yukon, Yukon XL, Denali) 2001 GMC Sierra C3 2002 GMC Sierra Denali 2002 Cadillac Escalade, Escalade EXT Condition Some customers may comment that they cannot control the HVAC system modes and/or the temperature. These concerns may be intermittent. Cause There may be poor terminal contact and/or bent terminals in connectors C206 (RPO C68 automatic HVAC controls) or C296 (RPO C60 manual HVAC controls). Excessive tension on the wires due to the wiring harness being misrouted in the instrument panel carrier may cause these conditions. Correction 1. Remove the Air Bag fuse. 2. Disconnect the steering wheel and instrument panel (IP) air bag connectors. Refer to the SIR subsection of the Restraints section of the Service Manual for connector locations. 3. Remove the IP upper trim pad. 4. Locate connector C206 (6 cavities) or C296 (8 cavities). The connector is attached to a metal brace on the far right side of the IP carrier above the IP air distributor duct. 5. Inspect the routing of the wiring harness to the connector. The proper routing of the wiring harness is above the air distributor duct with no tension on the terminals in the connector. The routing is improper if the wiring harness is below the air distributor duct with excessive tension on the terminals in the connector. The excessive tension may cause poor terminal contact, resulting in open circuits, in the connector. The wires may also pull the terminals out of the connector or pull out of the terminal itself. 6. If the harness is routed properly, contact Technical Assistance for further information. 7. If the harness is misrouted, remove the connector from the brace. 8. Disconnect the connector. 9. Perform a pin drag test on the female terminals. 10. Inspect the male terminals for straightness. 11. Inspect the wire to terminal connection to insure that no wires have pulled out of the terminals. 12. Reroute the wiring harness above the air distributor duct. 13. Firmly reconnect and reseat the connector. 14. Reattach the connector to the metal brace. 15. Reinstall the IP upper trim pad. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 01-01-39-007 > Jan > 02 > A/C - Loss of Mode/Temperature Control > Page 10999 16. Turn Off the ignition and reconnect the steering wheel and IP air bags. 17. Reinstall the Air Bag fuse. 18. Turn ON the ignition and verify that the air bag light flashes seven times and goes out. 19. Clear any diagnostic trouble codes that may have been set. 20. Verify proper operation of the HVAC system mode and temperature controls. Warranty Information For vehicles repaired under warranty. use the table as shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-01-37-001 > Jan > 04 > A/C - Control Knob Replacement Availability Control Assembly: All Technical Service Bulletins A/C - Control Knob Replacement Availability Bulletin No.: 04-01-37-001 Date: January 06, 2004 INFORMATION Subject: HVAC Control Knob Replacement Models: 2000-2004 All Passenger Cars and Light Duty Trucks 2003-04 HUMMER H2 HVAC Control Knob Availability Important: If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. The various knobs used on the HVAC controls of most GM vehicles are available for purchase separately from the HVAC head units. If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. Please use only the labor operation code listed below when replacing an HVAC control knob. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Component Locations Control Assembly: Component Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Component Locations > Page 11007 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Component Locations > Page 11008 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Component Locations > Page 11009 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Component Locations > Page 11010 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Component Locations > Page 11011 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Component Locations > Page 11012 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Component Locations > Page 11013 Control Assembly: Connector Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Component Locations > Page 11014 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Systems - Manual Control Assembly: Diagrams HVAC Systems - Manual HVAC Control Module - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 11017 HVAC Control Assembly - Front Auxiliary (W/O Sunroof - W/Heat And A/C) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 11018 HVAC Control Assembly - Front Auxiliary (A/C Only) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 11019 HVAC Control Assembly - Front Auxiliary (W/O Sunroof - W/Heat And A/C) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 11020 HVAC Control Assembly - Rear Auxiliary (W/Heat And A/C Utilities) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 11021 HVAC Control Assembly - Rear Auxiliary (A/C Only) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 11022 HVAC Blower Motor Control Switch - C1 (Part Of HVAC Control Assembly) (Part 1 Of 2) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 11023 Control Assembly: Diagrams HVAC Systems - Automatic HVAC Control Module - Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 11024 HVAC Control Module - Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 11025 HVAC Control Assembly - Front Auxiliary Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Systems - Manual > Page 11026 HVAC Control Assembly - Front Auxiliary (W/Sunroof) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > HVAC System - Automatic Control Assembly: Service and Repair HVAC System - Automatic Blower Motor Control Processor Replacement - HVAC System - Automatic REMOVAL PROCEDURE 1. If equipped remove the sound insulator panel. 2. Disconnect the electrical connector at the blower motor. 3. Disconnect the electrical connector (4) from the blower motor control processor (2). 4. Remove the blower motor control processor retaining screws (3) from the HVAC module (1). 5. Remove the blower motor control processor (2) from the HVAC module (1). INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11029 1. Install the blower motor control processor (2) to the HVAC module (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor control processor retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector (4) to the blower motor control processor (2). 4. Connect the electrical connector at the blower motor. 5. If equipped, install the sound insulator panel. Blower Motor Processor Replacement - Auxiliary REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11030 1. Remove the right rear quarter trim panel. 2. Disconnect the electrical connector from the blower motor processor (1). 3. Remove the retaining screws from the blower motor processor (1). 4. Remove the blower motor processor (1) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the blower motor processor (1) to the HVAC module (2). 2. Install the retaining screws to the blower motor processor (1). 3. Connect the electrical connector to the blower motor processor (1). 4. Install the right rear quarter trim panel. HVAC Control Assembly Replacement - Front Auxiliary REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11031 1. Remove the console roof screw. 2. Support the console (1) and remove it from the headliner. 3. Disconnect the electrical connectors (3). 4. Remove the console (1) from the vehicle. 5. Remove the HVAC control assembly (2) from the console (1) by depressing the 4 tabs on the backside of the controller. INSTALLATION PROCEDURE 1. Install the HVAC control assembly (2) to the console (1). 2. Connect the electrical connectors (3). 3. Install the console (1) to the headliner. 4. Install the console roof screw. 5. Calibrate the HVAC module actuators. Refer to Re-Calibrating Actuators. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11032 Control Assembly: Service and Repair HVAC System - Manual HVAC Control Assembly Replacement REMOVAL PROCEDURE 1. Remove the instrument cluster trim plate bezel. 2. Remove the instrument panel storage tray. 3. Remove the accessory switch assembly from the instrument panel. 4. Remove the screws from the HVAC control assembly. 5. Remove the HVAC control assembly, with the following procedure: 5.1. Release the retaining tabs. 5.2. Pull the control head out of the instrument panel carrier. 6. Disconnect the electrical connectors from the HVAC control assembly. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the HVAC control assembly. 2. Install the HVAC control assembly. 3. Install the accessory switch assembly to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws from the HVAC control assembly. Tighten Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11033 Tighten the screws to 1.9 N.m (17 lb in). 5. Install the instrument panel storage tray. 6. Install the instrument cluster trim plate bezel. Front Overhead Control A/C Only REMOVAL PROCEDURE 1. Remove the console roof screw. 2. Support the console and remove the console from the headliner. 3. Disconnect the electrical connectors. 4. Remove the console from the vehicle. 5. Remove the HVAC control assembly from the console. INSTALLATION PROCEDURE 1. Install the HVAC control assembly to the console. 2. Connect the electrical connectors. 3. Install the console to the headliner. 4. Install the console roof screw. 5. Calibrate the HVAC module actuators. Refer to Re-Calibrating Actuators in HVAC Systems Automatic. Front Overhead Control Heat and A/C REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11034 1. Remove the console roof screw. 2. Support the console and remove the console from the headliner. 3. Disconnect the electrical connectors. 4. Remove the console from the vehicle. 5. Remove the HVAC control assembly from the console. INSTALLATION PROCEDURE 1. Install the HVAC control assembly to the console. 2. Connect the electrical connectors. 3. Install the console to the headliner. 4. Install the console roof screw. 5. Calibrate the HVAC module actuators. Refer to Re-Calibrating Actuators in HVAC Systems - Automatic. HVAC Control Assembly Replacement - Rear Auxiliary REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11035 1. Separate the front of the console (1) from the headliner. 2. Push the assembly rearward and pull down in order to access the retaining tabs. 3. Remove the HVAC control assembly (2) by releasing the tabs at the rear of the control and push out from the rear. 4. Disconnect the electrical connector (3). INSTALLATION PROCEDURE 1. Connect the electrical connector (3). 2. Install the HVAC control assembly (2) to the console (1). 3. Install the console (1) to the headliner. 4. Calibrate the HVAC module actuators. Refer to Re-Calibrating Actuators in HVAC Systems - Automatic. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 04-01-39-007 > Jun > 04 > A/C - Loss of Mode or Temperature Control Control Module HVAC: Customer Interest A/C - Loss of Mode or Temperature Control Bulletin No.: 04-01-39-007 Date: June 17, 2004 TECHNICAL Subject: Loss Of HVAC System Mode and/or Temperature Control (Replace HVAC Control Module) Models: 2002 Cadillac Escalade, Escalade EXT 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalanche 1999-2002 GMC Denali, Sierra, Yukon, Yukon XL 2001 GMC Sierra C3 2002 GMC Sierra Denali with Automatic HVAC System (RPO C68) Condition Some customers may comment that they cannot control the HVAC system modes and/or the temperature. These concerns may be intermittent. Cause An HVAC control module logic lock-up may be the cause of these conditions. Correction Important: Prior to replacing the HVAC control head, review Corporate Bulletin Number 01-01-39-007. Replace the HVAC control module. Refer to the HVAC Control Module Replacement procedure in the HVAC System - Automatic sub-section of the Service Manual. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 04-01-39-007 > Jun > 04 > A/C - Loss of Mode or Temperature Control > Page 11044 Part Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 04-01-39-007 > Jun > 04 > A/C Loss of Mode or Temperature Control Control Module HVAC: All Technical Service Bulletins A/C - Loss of Mode or Temperature Control Bulletin No.: 04-01-39-007 Date: June 17, 2004 TECHNICAL Subject: Loss Of HVAC System Mode and/or Temperature Control (Replace HVAC Control Module) Models: 2002 Cadillac Escalade, Escalade EXT 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalanche 1999-2002 GMC Denali, Sierra, Yukon, Yukon XL 2001 GMC Sierra C3 2002 GMC Sierra Denali with Automatic HVAC System (RPO C68) Condition Some customers may comment that they cannot control the HVAC system modes and/or the temperature. These concerns may be intermittent. Cause An HVAC control module logic lock-up may be the cause of these conditions. Correction Important: Prior to replacing the HVAC control head, review Corporate Bulletin Number 01-01-39-007. Replace the HVAC control module. Refer to the HVAC Control Module Replacement procedure in the HVAC System - Automatic sub-section of the Service Manual. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 04-01-39-007 > Jun > 04 > A/C Loss of Mode or Temperature Control > Page 11050 Part Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 11051 Blower Motor Control Processor - Auxiliary (Tahoe/Yukon) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic Control Module HVAC: Service and Repair HVAC System - Automatic HVAC Control Module Replacement REMOVAL PROCEDURE 1. Remove the instrument panel accessory trim plate. 2. Remove the screws from the HVAC control module. 3. Depress the control assembly retaining tabs and remove the HVAC control module from the instrument panel. 4. Disconnect the electrical connectors from the HVAC control module. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the HVAC control module. 2. Install the HVAC control module into the instrument panel, ensuring that the HVAC control module retaining tabs lock into place. NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Install the screws to the HVAC control module. Tighten Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11054 Tighten the screws to 1.9 N.m (17 lb in). 4. Install the instrument panel accessory trim plate. Important: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. 5. Start the vehicle and let run for one minute. HVAC Control Module Replacement - Auxiliary REMOVAL PROCEDURE 1. Separate the front of the console (1) from the headliner by pushing forward and pulling down in front. 2. Remove the HVAC control assembly (2) by releasing the tabs at the rear of the control. Push out from the back through the console. 3. Disconnect the electrical connector (3). INSTALLATION PROCEDURE 1. Connect the electrical connector (3). 2. Install the HVAC control assembly (2) to the console (1). 3. Install the console to the headliner. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11055 Control Module HVAC: Service and Repair HVAC System - Manual HVAC CONTROL PROCESSOR REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the auxiliary rear HVAC control assembly. 2. Remove the auxiliary HVAC control processor (2) from the bracket (3). 3. Remove the cover from the auxiliary HVAC control processor (2). 4. Remove the auxiliary HVAC control processor (2) from the box (1). INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11056 1. Install the auxiliary HVAC control processor (2) to the box. (1) 2. Install the cover to the auxiliary HVAC control processor (2). 3. Install the auxiliary HVAC control processor (2) to the bracket (3). 4. Install the auxiliary rear HVAC control assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement A/C Coupler O-ring: Service and Repair O-Ring Replacement REMOVAL PROCEDURE 1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure - For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). - For banjo style fittings remove the bolt retaining the banjo type fitting. 2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 5. Cap or tape the A/C refrigerant components. 6. Discard the O-ring seal. INSTALLATION PROCEDURE 1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. IMPORTANT: DO NOT reuse O-ring seals. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement > Page 11062 5. Carefully slide the new O-ring seal onto the A/C refrigerant component. 6. The O-ring seal must be fully seated. 7. Assemble the A/C components. Refer to the appropriate repair procedure. - For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to - For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement > Page 11063 A/C Coupler O-ring: Service and Repair Sealing Washer Replacement REMOVAL PROCEDURE 1. Remove the seal washer from the A/C refrigerant component. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. IMPORTANT: DO NOT reuse sealing washer. 4. Discard the sealing washer. INSTALLATION PROCEDURE IMPORTANT: Flat washer type seals do not require lubrication. 1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. 5. The washer must completely bottom against the surface of the fitting. IMPORTANT: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement > Page 11064 6. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Air Temperature Sensor-Upper Auxiliary Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Air Temperature Sensor-Upper Auxiliary > Page 11069 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper REMOVAL PROCEDURE 1. Remove the radio. 2. Disconnect the electrical connector from the upper duct air temperature sensor. 3. Remove the upper duct air temperature sensor from the air duct by prying out of the duct. INSTALLATION PROCEDURE 1. Install the upper duct air temperature sensor to the air duct. 2. Connect the electrical connector to the upper duct air temperature sensor. 3. Install the radio. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper > Page 11072 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper Auxiliary REMOVAL PROCEDURE 1. Remove the right side C-Pillar Trim Panel. 2. Disconnect the electrical connector from the rear upper A/C temperature sensor (11). 3. Remove the rear upper A/C temperature sensor (11) from the air distribution duct. INSTALLATION PROCEDURE 1. Install the rear upper A/C temperature sensor (11) to the air distribution duct. 2. Connect the electrical connector to the rear upper A/C temperature sensor (11). 3. Install the right side C-Pillar Trim Panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper > Page 11073 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower REMOVAL PROCEDURE 1. Remove the lower duct air temperature sensor (3) and wiring harness assembly from the floor air outlet (2). 2. Disconnect the electrical connector from the lower duct air temperature sensor (3). INSTALLATION PROCEDURE 1. Connect the lower duct air temperature sensor (3) to the electrical connector. 2. Install the lower duct air temperature sensor (3) and wiring harness assembly to the floor air outlet (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper > Page 11074 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Auxiliary REMOVAL PROCEDURE 1. Remove the right side C-Pillar Trim Panel. 2. Disconnect the electrical connector from the auxiliary lower A/C temperature sensor (10). 3. Remove the auxiliary lower A/C temperature sensor (10) from the air distribution duct. INSTALLATION PROCEDURE 1. Install the rear lower A/C temperature sensor (10) to the air distribution duct. 2. Connect the electrical connector to the rear lower A/C temperature sensor (10). 3. Install the right side C-Pillar Trim Panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 11083 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 11084 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 11090 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 11091 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 11092 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement Evaporator Core: Service and Repair Evaporator Core Replacement REMOVAL PROCEDURE 1. Remove the heater/vent module. See: Housing Assembly HVAC/Service and Repair 2. Remove the heater/vent module screws. 3. Separate the heater/vent module. 4. Remove the evaporator core from the heater/vent module. INSTALLATION PROCEDURE 1. Install the evaporator core to the heater/vent module. 2. Install the heater/vent module halves. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the heater/vent module screws. Tighten Tighten the screws to 1.6 Nm (14 lb in). 4. Install the heater/vent module. 5. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fittings of the component using the J 39400-A. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 11095 Evaporator Core: Service and Repair Evaporator Core Replacement - Auxiliary TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the auxiliary HVAC module (4) from the vehicle. See: Housing Assembly HVAC/Service and Repair 2. Remove the air temperature actuator (1) from the auxiliary HVAC module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 11096 3. Remove the heater core cover (1) from the auxiliary HVAC module. 4. Remove the heater core (1) from the auxiliary HVAC module. 5. Remove the lower module cover from the auxiliary HVAC module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 11097 6. Remove the evaporator core from the lower module cover. INSTALLATION PROCEDURE 1. Install the evaporator core to the lower module cover. 2. Install the lower module cover to the auxiliary HVAC module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 11098 3. Install the heater core (1) to the auxiliary HVAC module. 4. Install the heater core cover (1) to the auxiliary HVAC module. 5. Install the air temperature actuator (1) to the auxiliary HVAC module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 11099 6. Install the auxiliary HVAC module assembly (4) to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair Expansion Block/Orifice Tube: Service and Repair TOOLS REQUIRED - J 26549-E Orifice Tube Remover - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Loosen the nut from the evaporator tube fitting. 3. Use the J 26549-E in order to remove the orifice tube (1) from the evaporator tube (2). 4. Cap or plug the open line. INSTALLATION PROCEDURE 1. Uncap or unplug the evaporator tube. 2. Install the new O-ring seal. 3. Install the short screen end of the new orifice (1) into the evaporator tube. NOTE: Refer to Fastener Notice in Service Precautions. 4. Connect the evaporator tube at the fitting. Tighten Tighten the fitting to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Page 11103 5. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fittings of the repaired component using J 39400-A. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair Expansion Valve: Service and Repair THERMAL EXPANSION VALVE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the evaporator core. 2. Carefully remove the sealer packed around the Thermo Expansion Valve (TXV). Reuse the sealer on the replacement TXV. IMPORTANT: Note the mounting location and the orientation of the tube on the core. 3. Remove the clip retaining the capillary tube to the evaporator core. 4. Disconnect the Evaporator tube connections from the TXV. 5. Remove the TXV from the tubes. INSTALLATION PROCEDURE 1. Install the Thermal Expansion Valve (TXV) to the tubes. NOTE: Refer to Fastener Notice in Service Precautions. 2. Connect the Evaporator tube connections from the TXV. Tighten Tighten the tube connections to 28 N.m (21 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Page 11107 IMPORTANT: Install the clip and the tube in the location and the orientation as noted during the disassembly. 3. Install the clip in order to retain the capillary tube to the evaporator core. 4. Pack sealer around the TXV in the manner found during the disassembly. 5. Install the evaporator core. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 11112 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 11113 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 11114 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement Heater Core: Service and Repair Heater Core Replacement REMOVAL PROCEDURE 1. Remove the heater/vent module. See: Housing Assembly HVAC/Service and Repair 2. Remove the heater core cover screws. 3. Remove the heater core cover. 4. Remove the heater core. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 11117 1. Install the heater core. 2. Install the heater core cover. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install heater core cover screws. Tighten Tighten the screws to 1.6 Nm (14 lb in). 4. Install the heater/vent module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 11118 Heater Core: Service and Repair Heater Core Replacement - Auxiliary REMOVAL PROCEDURE 1. Remove the auxiliary HVAC module (4) from the vehicle. See: Housing Assembly HVAC/Service and Repair 2. Remove the air temperature actuator (1) from the auxiliary HVAC module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 11119 3. Remove the heater core cover (1) from the auxiliary HVAC module. 4. Remove the heater core (1) from the auxiliary HVAC module. INSTALLATION PROCEDURE 1. Install the heater core (1) to the auxiliary HVAC module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 11120 2. Install the heater core cover (1) to the auxiliary HVAC module. 3. Install the air temperature actuator (1) to the auxiliary HVAC module. 4. Install the auxiliary HVAC module assembly (4) to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Heater Hose: Service and Repair Heater Pipe Replacement - Auxiliary REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the auxiliary heater pipes (1, 2) from the heater inlet and outlet tees (3, 4). 3. Loosen the right front wheelhouse to gain access to the clamp behind the wheelhouse. Refer to Wheelhouse Panel Replacement in Body Front End. 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Remove the auxiliary heater pipes (2, 3) from the auxiliary heater core. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 11125 6. Remove the heater/A/C tubes retaining nut (4) from the stud (1) at the frame (6). 7. Remove the auxiliary heater pipes (2) from the clamps (5). 8. Remove the auxiliary heater pipes from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary healer pipes to the vehicle. 2. Install the auxiliary heater pipes (2) to the clamps (5). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the heater/A/C tubes retaining nut (4)10 the stud (1) at the frame (6). Tighten Tighten the heater/A/C tubes retaining nut to 7 N.m (62 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 11126 4. Install the auxiliary heater pipes (2, 3) to the auxiliary heater core. 5. Lower the vehicle. Refer to Lifting and Jacking the Vehicle. 6. Install the right front wheelhouse. 7. Install the auxiliary heater pipes (1, 2)10 the heater inlet and outlet tees (3, 4). 8. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 11127 Heater Hose: Service and Repair Heater Hose Replacement - Inlet REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. 5. Pull the connection apart. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 11128 6. Remove the inlet heater hose from the water pump. 7. Remove the inlet heater hose. INSTALLATION PROCEDURE 1. Install the inlet heater hose. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 11129 2. Install the inlet heater hose to the water pump. 3. Connect the heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hoses to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 11130 Heater Hose: Service and Repair Heater Hose Replacement - Outlet REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. 5. Pull the connection apart. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 11131 6. Remove the outlet heater hose from the water pump. 7. Reposition the outlet heater hose clamp at the surge tank. 8. Remove the outlet heater hose from the surge tank. 9. Remove the outlet heater hose. INSTALLATION PROCEDURE 1. Install the outlet heater hose. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 11132 2. Install the outlet heater hose to the water pump. 3. Install the outlet heater hose to the surge tank. 4. Install the outlet heater hose clamp to the surge tank. 5. Connect the heater and surge tank hoses to the heater core. Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Install the heater and surge tank hoses to the mounting clip. 7. Install the air intake tube. 8. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 11133 Heater Hose: Service and Repair Heater and A/C Pipe Repair - Auxiliary TOOLS REQUIRED J 41425 A/C Line Repair Kit Do not service the rear A/C or heater lines as a complete unit. Service the rear A/C or heater lines as a sectional repair. You can obtain the various sections of line through GMSPO. Use the J 41425 when any of the following actions damage the rear A/C or heater lines: - Rub-through - Collision damage - Leakage in the system Minimum Tube Length Required Table IMPORTANT: When you section the rear A/C or heater lines, ensure that the correct minimum length remains in the straight part of the line on both sides of the splice. Follow the Straight Line Repair procedure in order to repair line damage in a straight section of line. Follow the Line Sectioning Repair procedure in order to repair any damage in a bend area. Do not repair the rear A/C or heater lines in a bend area, replace the lines. Maintaining the original line shape will prevent vibrations and rub-through. Straight Line Repair 1. Recover the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. 2. Drain the coolant, if repairing the heater lines. Refer to Draining and Filling Cooling System in Engine Cooling. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Locate the area that requires repair. 5. Obtain a length of replacement line to make the repair. 6. Use a tubing cutter in order to cut and remove the section of damaged line. IMPORTANT: The length of the replacement line must be the same as the section being replaced. 7. Use a tubing cutter in order to cut the replacement line to length. 8. Use the cleaning pad from the J41425 in order to clean any burrs or grease from the line ends. Be sure to clean at least 19 mm (0.75 in) from the line ends. 9. Use the LOK prep sealant in order to prep the line ends. 10. Apply one drop of the J 41425-3 sealing compound to the outside of each end of the line. 11. Insert the line ends into the LOK fitting. 12. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines. 13. Install the correct LOK fitting jaws into the J 41425-1 tool. 14. Install the J 41425-1 tool over the LOK connectors. Verify that the LOK connector ends are positioned in the counter bores of the jaws. IMPORTANT: Hold the J 41425-1 tool body with a 3/8" breaker bar. 15. Tighten the forcing screw of the J 41425-1 tool. When fully seated, the LOK connector collars will bottom out on the center shoulder of the LOK fitting. 16. Loosen the forcing screw and remove the J 41425-1 tool from the repaired line. 17. Repeat Step 8 through Step 16 to repair the other end of the line. 18. Verify that the LOK fittings are correctly installed. 19. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary > Page 11134 20. Refill the coolant, if drained. Refer to Draining and Filling Cooling System in Engine Cooling. 21. Evacuate and recharge the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. Line Sectioning Repair 1. Recover the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. 2. Drain the coolant, if repairing the heater lines. Refer to Draining and Filling Cooling System in Engine Cooling. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Obtain a new A/C or heater line for sectioning. IMPORTANT: Stagger the splices if repairing more than one line. 5. Scribe a mark on the line that will be sectioned. 6. Use a tubing cutter in order to cut the line or lines being replaced. 7. Remove the section of line being replaced from the vehicle. IMPORTANT: The length of the replacement line must be the same as the line being replaced. 8. Install the replacement line to the vehicle. 9. Use a tubing cutter in order to cut the replacement line to length. 10. Use the cleaning pad from the J 41425 in order to clean any burrs or grease. Be sure to clean at least 19 mm (0.75 in) from the A/C line. 11. Use the LOK prep sealant in order to prep the A/C or heater line. 12. Apply one drop of the J 41425-3 sealing compound to the outside of each line end. 13. Insert the line ends into the LOK fitting. 14. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines. 15. Install the correct LOK fitting jaws into the J41425-1 tool. 16. Install the J 41425-1 tool over the LOK connectors. Verify that the LOK connector ends are positioned in the counter bores of the jaws. 17. Hold the tool body with a 3/8" breaker bar. Turn the forcing screw until both of the connector collars bottom on the center shoulder of the LOK fitting. 18. Loosen the forcing screw. Remove the tool from the repaired line. 19. Verify that the LOK fitting is correctly installed. 20. Lower the vehicle. 21. Refill the coolant, if drained. Refer to Draining and Filling Cooling System in Engine Cooling. 22. Evacuate and recharge the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > Compressor Pressure Relief Valve Removal (HT6/HD6/HU6) High Pressure Safety Valve HVAC: Service and Repair Compressor Pressure Relief Valve Removal (HT6/HD6/HU6) TOOLS REQUIRED J 34992 Compressor Holding Fixture 1. Install the compressor onto the J 34992. 2. Remove the pressure relief valve (5) from the rear head of the compressor. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > Compressor Pressure Relief Valve Removal (HT6/HD6/HU6) > Page 11139 High Pressure Safety Valve HVAC: Service and Repair Compressor Pressure Relief Valve Install (HT6/HD6/HU6) TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 39400-A Halogen Leak Detector 1. Clean the valve seat area on the rear head. 2. Lubricate the O-ring of the new pressure relief valve (5) and the O-ring assembly using new 525 viscosity refrigerant oil. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the new pressure relief valve (5). Tighten Tighten the new valve to 9.0 N.m (80 lb in). 4. Evacuate and recharge the system using the J 43600. 5. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 Hose/Line HVAC: Customer Interest Suspension - Service Ride Control Message/DTC C0580 Bulletin No.: 03-03-11-001 Date: July 22, 2003 TECHNICAL Subject: Service Ride Control Message Displayed, DTC C0580 Set (Replace Right Front Shock Absorber Solenoid Connector and Install New A/C Suction Hose and Auxiliary A/C Evaporator Hose) Models: 2002-2003 Cadillac Escalade 2003 Cadillac Escalade ESV 2001-2003 Chevrolet Suburban, Tahoe 2001-2003 GMC Yukon, Yukon XL with Rear Air Conditioning System (RPO C69) and Real Time Damping Chassis Package (RPO Z55) Condition Some customers may comment on the Service Ride Control message being displayed. Upon investigation, the technician may find DTC C0580 set. Cause Poor clearance between the auxiliary A/C evaporator hose and the right front shock absorber damper solenoid connector may be the cause of this condition. Contact may occur damaging the connector and causing a poor connection at the damper solenoid. Correction Replace the right front shock absorber solenoid connector and install a new A/C suction hose and auxiliary A/C evaporator hose. These new A/C hoses will provide proper routing to prevent contact between the auxiliary A/C evaporator hose and the right front shock absorber damper solenoid connector. Use the procedure listed below. 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 3. Remove the right front wheel assembly. 4. Remove the right front wheelhouse panel. 5. Remove the nut and the auxiliary evaporator hose from the accumulator line block. 6. Remove the nut and the suction hose from the accumulator. 7. Remove the bolt and the suction hose from the compressor. 8. Install the new suction hose and bolt to the compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). 9. Install the new suction hose and nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 10. Release 4 line retaining clamps, starting at the wheelhouse and along the underbody towards the rear of vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 > Page 11148 11. From under the vehicle, mark the location on the auxiliary evaporator line where the line will be cut. Using the forward running board bracket as a reference, mark the location inline with the bracket-to-body bolt (1). If the vehicle is not equipped with running boards, mark the location inline with the bolt hole. 12. Using a tubing cutter, cut the marked section of the auxiliary evaporator line. 13. Remove the front section of the auxiliary evaporator hose from the vehicle and discard. 14. Install the new front section of the auxiliary evaporator hose into the vehicle. 15. On both sections of the auxiliary evaporator line, cut back the plastic coating approximately 76 mm (3 in). 16. Splice in the new front section of the auxiliary evaporator hose using J 41425 A/C Line Repair Kit and J 41425-750 splice. Refer to the Heater and A/C Pipe Repair-Auxiliary procedure in the Service Manual. 17. Install the auxiliary evaporator hose to the accumulator line block and nut. Tighten Tighten the nut to 16 N.m (12 lb ft). 18. Secure the line retaining clamps. 19. Install the wheelhouse panel. 20. Install the wheel assembly. 21. Lower the vehicle. 22. Inject the oil into the A/C system that was removed during the recovery process using J 45037 A/C Oil Injection Kit. 23. Evacuate and recharge the refrigerant. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. 24. Leak test the fitting and splice using J 39400-A Halogen Leak Detector. 25. Replace the right front shock absorber solenoid connector using service connector, P/N 88986417. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 > Page 11149 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 Hose/Line HVAC: All Technical Service Bulletins Suspension - Service Ride Control Message/DTC C0580 Bulletin No.: 03-03-11-001 Date: July 22, 2003 TECHNICAL Subject: Service Ride Control Message Displayed, DTC C0580 Set (Replace Right Front Shock Absorber Solenoid Connector and Install New A/C Suction Hose and Auxiliary A/C Evaporator Hose) Models: 2002-2003 Cadillac Escalade 2003 Cadillac Escalade ESV 2001-2003 Chevrolet Suburban, Tahoe 2001-2003 GMC Yukon, Yukon XL with Rear Air Conditioning System (RPO C69) and Real Time Damping Chassis Package (RPO Z55) Condition Some customers may comment on the Service Ride Control message being displayed. Upon investigation, the technician may find DTC C0580 set. Cause Poor clearance between the auxiliary A/C evaporator hose and the right front shock absorber damper solenoid connector may be the cause of this condition. Contact may occur damaging the connector and causing a poor connection at the damper solenoid. Correction Replace the right front shock absorber solenoid connector and install a new A/C suction hose and auxiliary A/C evaporator hose. These new A/C hoses will provide proper routing to prevent contact between the auxiliary A/C evaporator hose and the right front shock absorber damper solenoid connector. Use the procedure listed below. 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 3. Remove the right front wheel assembly. 4. Remove the right front wheelhouse panel. 5. Remove the nut and the auxiliary evaporator hose from the accumulator line block. 6. Remove the nut and the suction hose from the accumulator. 7. Remove the bolt and the suction hose from the compressor. 8. Install the new suction hose and bolt to the compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). 9. Install the new suction hose and nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 10. Release 4 line retaining clamps, starting at the wheelhouse and along the underbody towards the rear of vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 > Page 11155 11. From under the vehicle, mark the location on the auxiliary evaporator line where the line will be cut. Using the forward running board bracket as a reference, mark the location inline with the bracket-to-body bolt (1). If the vehicle is not equipped with running boards, mark the location inline with the bolt hole. 12. Using a tubing cutter, cut the marked section of the auxiliary evaporator line. 13. Remove the front section of the auxiliary evaporator hose from the vehicle and discard. 14. Install the new front section of the auxiliary evaporator hose into the vehicle. 15. On both sections of the auxiliary evaporator line, cut back the plastic coating approximately 76 mm (3 in). 16. Splice in the new front section of the auxiliary evaporator hose using J 41425 A/C Line Repair Kit and J 41425-750 splice. Refer to the Heater and A/C Pipe Repair-Auxiliary procedure in the Service Manual. 17. Install the auxiliary evaporator hose to the accumulator line block and nut. Tighten Tighten the nut to 16 N.m (12 lb ft). 18. Secure the line retaining clamps. 19. Install the wheelhouse panel. 20. Install the wheel assembly. 21. Lower the vehicle. 22. Inject the oil into the A/C system that was removed during the recovery process using J 45037 A/C Oil Injection Kit. 23. Evacuate and recharge the refrigerant. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. 24. Leak test the fitting and splice using J 39400-A Halogen Leak Detector. 25. Replace the right front shock absorber solenoid connector using service connector, P/N 88986417. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-03-11-001 > Jul > 03 > Suspension - Service Ride Control Message/DTC C0580 > Page 11156 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hose/Line HVAC: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: All Technical Service Bulletins Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hose/Line HVAC: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's > Page 11162 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hose/Line HVAC: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's > Page 11168 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 11169 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement Hose/Line HVAC: Service and Repair Evaporator Tube Replacement TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube nut from the evaporator. 3. Disconnect the evaporator tube from the evaporator. 4. Remove the evaporator tube nut from the auxiliary A/C tube (if equipped). 5. Disconnect the evaporator tube from the auxiliary A/C tube (if equipped). 6. Remove the right park/turn signal lamp. 7. Remove the grille from the vehicle. 8. Remove the evaporator tube nut from the condenser. 9. Disconnect the evaporator tube from the condenser. 10. Remove the evaporator tube from the vehicle. 11. Discard all of the used sealing washers. Cap all of the open connections. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 11172 1. Connect the evaporator tube to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the evaporator tube nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 3. Install the grille to the vehicle. 4. Install the right park/turn signal lamp. 5. Connect the evaporator tube to the auxiliary A/C tube using new sealing washers (if equipped). 6. Install the evaporator tube nut to the auxiliary A/C tube (if equipped). Tighten Tighten the nut to 16 N.m (12 lb ft). 7. Connect the evaporator tube to the evaporator. 8. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 9. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 10. Leak test the fittings of the components using the J 39400-A. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 11173 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the suction hose mounting bolt from the A/C compressor. 3. Remove the suction hose (2) from the A/C compressor. 4. Remove the suction hose nut from the accumulator. 5. Remove the suction hose from the accumulator. 6. Remove the suction hose assembly from the vehicle. 7. Discard all of the used sealing washers. Cap the system openings. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 11174 1. Install the suction hose to the vehicle. 2. Install the suction hose to the accumulator. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 4. Install the suction hose (2) to the compressor using new sealing washers. 5. Install the suction hose mounting bolt to the A/C compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). 6. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fittings of the component using the J 39400-A. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 11175 Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the discharge hose mounting bolt (2) from the A/C compressor. 3. Remove the discharge hose (1) from the A/C compressor. 4. Remove the upper radiator baffle. 5. Remove the discharge hose nut from the condenser. 6. Remove the discharge hose from the condenser. 7. Disconnect the electrical connector from the A/C recirculation switch. 8. Remove the discharge hose from the vehicle. 9. Discard all of the used sealing washers. Cap the system openings. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 11176 1. Install the discharge hose (1) to the vehicle. 2. Connect the electrical connector to the A/C recirculation switch. 3. Install the discharge hose to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the discharge hose nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 5. Install the upper air baffle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 11177 6. Install the discharge hose (1) to the A/C compressor using new sealing washers. 7. Install the discharge hose mounting bolt. Tighten Tighten the bolt to 16 N.m (12 lb ft). 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 11178 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement - Auxiliary TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the auxiliary A/C evaporator tubes (3) from the condenser tube (2) and the accumulator (5). 3. Loosen the right front wheelhouse to gain access to the clamp behind the wheelhouse. Refer to Wheelhouse Panel Replacement in Body Front End. 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Remove the retaining nut (2) and the auxiliary A/C evaporator tubes (3) from the auxiliary HVAC module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 11179 6. Remove the heater/A/C tubes retaining nut (4) from the stud (1) at the frame (6). 7. Remove the auxiliary A/C evaporator tubes (3) from the clamps (5). 8. Remove the auxiliary A/C evaporator tubes from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary A/C evaporator tubes to the vehicle. 2. Install the auxiliary A/C evaporator tubes (3) to the clamps (5). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the heater/A/C tubes retaining nut (4) to the stud (1) at the frame (6). Tighten Tighten the heater/A/C tubes retaining nut to 7 N.m (62 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement > Page 11180 4. Install the auxiliary A/C evaporator tubes (2, 3) and the retaining nut to the auxiliary HVAC module. Tighten Tighten the nut to 16 N.m (12 lb ft). 5. Lower the vehicle. Refer to Lifting and Jacking the Vehicle. 6. Install the right front wheelhouse. Refer to Wheelhouse Panel Replacement in Body Front End. 7. Install the auxiliary A/C evaporator tubes (3) to the condenser tube (2) and the accumulator (5). Tighten Tighten the nuts to 16 N.m (12 lb ft). 8. Recharge the refrigerant to the system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Component Locations Housing Assembly HVAC: Component Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Component Locations > Page 11185 Locations View (Auxiliary HVAC Module) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Component Locations > Page 11186 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Component Locations > Page 11187 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Component Locations > Page 11188 Locations View (Auxiliary HVAC Module) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Component Locations > Page 11189 Housing Assembly HVAC: Connector Locations Locations View (Auxiliary HVAC Module) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Component Locations > Page 11190 Locations View (Auxiliary HVAC Module) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Component Locations > Page 11191 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Air Flow Control Box - Heater Housing Assembly HVAC: Service and Repair Air Flow Control Box - Heater REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Reposition the inlet heater hose clamp from the heater core. 3. Remove the inlet heater hose from the heater core. 4. Reposition the outlet heater hose clamp from the heater core. 5. Remove the outlet heater hose from the heater core. 6. Remove the accumulator. 7. Remove the IP carrier. 8. Remove the heater/vent module drain hose. 9. Disconnect the electrical harnesses and the ground connections. 10. Remove the heater/vent module mounting nuts and the screws. 11. Remove the heater/vent module assembly from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Air Flow Control Box - Heater > Page 11194 1. Install the heater/vent module assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the heater/vent module mounting nuts. Tighten Tighten the nuts to 9 N.m (80 lb in). 3. Install the heater/vent module mounting screws. Tighten Tighten the screws to 4 N.m (35 lb in). 4. Connect the electrical harnesses and the ground connections. 5. Install the heater/vent module drain hose. 6. Install the IP carrier. 7. Install the accumulator. 8. Install the outlet heater hose to the heater core. 9. Reposition the outlet heater hose clamp to the heater core. 10. Install the inlet heater hose to the heater core. 11. Reposition the inlet heater hose clamp to the heater core. 12. Fill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 13. Leak test the fitting of the repaired component using J 39400-A Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Air Flow Control Box - Heater > Page 11195 Housing Assembly HVAC: Service and Repair Heater/Vent Module Replacement REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Reposition the inlet heater hose clamp from the heater core. 3. Remove the inlet heater hose from the heater core. 4. Reposition the outlet heater hose clamp from the heater core. 5. Remove the outlet heater hose from the heater core. 6. Remove the accumulator. 7. Remove the IP carrier. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel (I/P) Carrier Replacement 8. Remove the heater/vent module drain hose. 9. Disconnect the electrical harnesses and the ground connections. 10. Remove the heater/vent module mounting nuts and the screws. 11. Remove the heater/vent module assembly from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Air Flow Control Box - Heater > Page 11196 1. Install the heater/vent module assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the heater/vent module mounting nuts. Tighten Tighten the nuts to 9 N.m (80 lb in). 3. Install the heater/vent module mounting screws. Tighten Tighten the screws to 4 N.m (35 lb in). 4. Connect the electrical harnesses and the ground connections. 5. Install the heater/vent module drain hose. 6. Install the IP carrier. 7. Install the accumulator. 8. Install the outlet heater hose to the heater core. 9. Reposition the outlet heater hose clamp to the heater core. 10. Install the inlet heater hose to the heater core. 11. Reposition the inlet heater hose clamp to the heater core. 12. Fill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 13. Leak test the fitting of the repaired component using J 39400-A Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Air Flow Control Box - Heater > Page 11197 Housing Assembly HVAC: Service and Repair HVAC Module Assembly Replacement - Auxiliary HVAC MODULE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Disconnect the heater lines (2, 3) from the auxiliary HVAC module at the underside of the vehicle. 5. Disconnect the air conditioning lines (2, 3) from the auxiliary HVAC module at the underside of the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Air Flow Control Box - Heater > Page 11198 6. Remove the nuts (2) from the studs (1) that secure the auxiliary HVAC module to the underside of the vehicle. 7. Remove the safety stands. 8. Lower the vehicle. 9. Remove the right rear quarter trim panel. 10. Remove the Real Time Damping (RTD) Module. Refer to Electronic Suspension Control Module Replacement (Tahoe/Yukon) or Electronic Suspension Control Module Replacement (Suburban/Yukon XL) in Real Time Damping-RTD. 11. Disconnect the electrical connectors. 12. Remove the fastener (5) for the upper auxiliary air duct (1). Carefully slide the duct up, into the headliner, until the bottom edge of the duct is above the air distributor duct. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Air Flow Control Box - Heater > Page 11199 13. Remove the fasteners (3) retaining the rear auxiliary HVAC module to the vehicle. 14. Remove the rear auxiliary HVAC module (4) from the vehicle and place it on a work surface. INSTALLATION PROCEDURE 1. Install the auxiliary HVAC module assembly (4) to the vehicle. 2. Install the two bolts (3) inside the vehicle in order to retain the case to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Air Flow Control Box - Heater > Page 11200 3. Install the upper auxiliary air duct (1) to the air distributor duct. Install the fastener (5). 4. Connect the electrical connectors. 5. Install the RTD Module. Refer to Electronic Suspension Control Module Replacement (Tahoe/Yukon) or Electronic Suspension Control Module Replacement (Suburban/Yukon XL) in Real Time Damping-RTD. 6. Install the right rear quarter trim panel. 7. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 8. Install the nuts (2) that secure the auxiliary HVAC module to the vehicle. Tighten Tighten the nuts to 9 N.m (80 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Air Flow Control Box - Heater > Page 11201 9. Install the air conditioning lines (2, 3) and the nut (4) to the auxiliary HVAC module. Tighten Tighten the nut to 16 N.m (12 lb ft). 10. Install the heater lines (2, 3) to the auxiliary HVAC module at the underside of vehicle. 11. Remove the safety stands. 12. Lower the vehicle. 13. Fill the engine coolant. Refer to Draining and Fuming Cooling System in Cooling System. 14. Recharge the refrigerant to the system. Refer to Refrigerant Recovery and Recharging. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 11206 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 11207 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Charge Refrigerant Charge .............................................................................................................................. ............................................................ 0.8 kg (1.8 lb) Refrigerant Charge Utility with Front and Rear A/C ....................................................................................................................................... 1.2 kg (2.7 lb) Refrigerant Charge Suburban with Front and Rear A/C .................................................................................................................................. 1.4 kg (3.0 lb) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 11210 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ..................................................................... R-134a Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 11211 Refrigerant: Service and Repair If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Flushing TOOLS REQUIRED J 43600 Air Conditioning Service Center - J 45268 Flush Adapter Kit - J 41447 Leak Detection Dye - J 41459 Leak Detection Dye Injector - J 42220 Universal Leak Detection Lamp IMPORTANT: Flushing is not intended to remove metal from the A/C system. Flushing is intended to remove the following: Contaminated PAG oil - Desiccant, following a desiccant bag failure - Overcharge of PAG oil - Refrigerant contamination IMPORTANT: Warmer engine or ambient temperature decreases the refrigerant recovery time during the A/C flush procedure. 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the orifice tube. 3. Connect the A/C lines with the orifice tube removed. 4. Remove the A/C compressor. 5. Inspect the end of the suction hose for a suction screen. 6. Remove the suction screen, if installed. 7. Install the J 45268-4 to the A/C compressor suction hose. 8. install the J 45268-5 to the A/C compressor discharge hose. 9. Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil. Perform the following procedure: IMPORTANT: The filter inside the J 45268-1 is serviceable. Remove and discard the check valve from the filter. 9.1. Service the filter with AC P/N GF 470, before each flush. Connect the J 45268-1 flush filter to the suction port of the J 45268-4 flush adapter. 9.2. Connect the blue hose from the J 43600 to the J 45268-1 flush filter adapter. 9.3. Connect the red hose from the J 43600 to the J 45268-5 flush adapter. 10. Reverse flow refrigerant flushing is recommended for desiccant bag failure. Perform the following procedure and replace the accumulator when the flush procedure is complete. IMPORTANT: The filter inside the J 45268-1 is serviceable. Remove and discard the check valve from the filter. 10.1. Service the filter with AC P/N GF 470, before each flush. Connect the J 45268-1 flush filter to the discharge port of the J 45268-5 flush adapter. 10.2. Connect the blue hose from the J 43600 to the J 45268-1 flush filter adapter. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 11212 10.3. Connect the red hose from the J 43600 to the suction port of the J 45268-4 flush adapter. 11. Flush the front A/C system. Follow the instructions supplied with the J 43600. Close the valve on the external refrigerant tank, before starting the flush process. IMPORTANT: Flush the front A/C system before flushing the auxiliary A/C system. 12. If the vehicle is equipped with rear A/C, flush the auxiliary A/C system separately. 13. Cut the orifice tube frame and screen, enough to access the end of the orifice tube Pinch off the orifice tube. IMPORTANT: Pinch off the orifice tube in order to prevent refrigerant flow to the front system during the auxiliary system flush. 14. Install the pinched orifice tube. 15. Remove the auxiliary TXV. 16. Install the J 45268-104. IMPORTANT: The auxiliary evaporator core can be flushed without totally reassembling into the auxiliary HVAC module. 17. Install the auxiliary evaporator core to the A/C lines. 18. Raise the vehicle. Refer to Lifting and Jacking the Vehicle on page. 19. Connect the auxiliary A/C lines to the auxiliary evaporator core. 20. Lower the vehicle. 21. Flush the auxiliary A/C system. Follow the instructions supplied with the J 43600. 22. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 23. Remove the auxiliary A/C lines from the auxiliary evaporator core. 24. Lower the vehicle. 25. Remove the J 45268-104. 26. Inspect the TXV for debris. Clean or replace as needed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 11213 27. Install the auxiliary TXV. 28. Remove the J 45268-4 from the A/C compressor suction hose. 29. Remove the J 45268-5 from the A/C compressor discharge hose. - Drain the PAG oil from the A/C compressor, through the suction and discharge ports. - Rotate the compressor input shaft to assist in draining the PAG oil from the A/C compressor. 30. Install the A/C compressor. 31. Install a new orifice tube. 32. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. IMPORTANT: Flushing will remove all of the PAG oil from the A/C system. 33. Add the total system capacity of PAG oil to the A/C system. Refer to Refrigerant System Capacities. IMPORTANT: Flushing will remove the fluorescent leak detection dye from the A/C system. 34. Add one bottle of J 41447 using the J 41459. 35. Leak test the fittings using the J 42220. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > Customer Interest: > 03-01-38-019A > Sep > 04 > A/C - Underhood Rattle Noise on Hard Acceleration Refrigerant Filter: Customer Interest A/C - Underhood Rattle Noise on Hard Acceleration File In Section: 01 - HVAC Bulletin No.: 03-01-38~019A Date: September, 2004 TECHNICAL Subject: Underhood Rattle Noise Heard On Acceleration (Check A/C System Performance and Compressor Operation) Models: 2003-2004 Cadillac CTS 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 2002-2004 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2002-2004 GMC Denali, Denali XL, Savana, Sierra, Yukon, Yukon XL 2002-2004 Commercial Upfitter Chassis Vehicles with Air Conditioning (A/C) This bulletin is being revised to update the service procedure and parts information. Please discard Corporate Bulletin Number 03-01-38-019 (Section 01 - HVAC). Condition Some customers may comment about an underhood rattle noise heard on acceleration or a sudden loss of A/C system performance. Cause This condition may be caused by liquid slugging of the A/C compressor. This condition may cause an internal failure in the A/C compressor. The serpentine belt tensioner and serpentine belt may also be damaged. Correction Technicians are to check the A/C system performance and compressor operation using the following repair procedure: 1. Open the hood and inspect the A/C compressor for damage and to see if the compressor is seized. Verify that the serpentine belt is not damaged or missing. If the A/C compressor is seized, proceed to Step 5. 2. Perform the A/C System Performance test. Refer to the Heating, Ventilation and Air Conditioning (HVAC) section of SI. Correct any performance concerns or refrigerant leaks that are found. 3. Inspect the vehicle for other possible sources of A/C compressor noise or performance concerns. Refer to Corporate Bulletin Number 01-01-38-013 for more information. 4. After all other possible sources of A/C compressor noise or performance concerns have been eliminated, only then should the A/C compressor be replaced. 5. Remove the A/C compressor. Refer to the A/C Compressor Replacement procedure in the HVAC section of SI. 6. Inspect the transmission cooler lines for damage due to contact from the serpentine belt. Replace the transmission cooler lines if necessary. 7. Install an inline A/C system filter. Refer to Corporate Bulletin Number 01-01-38-006C for more information about A/C system flushing and filter installation procedures. An A/C system flush is not to be done unless prior authorization is given by the GM Area Service Manager (in Canada, the District Service Manager). 8. Install an A/C Suction Screen. Refer to Corporate Bulletin Number 01-01-39-003A for more information about A/C suction screen repair recommendations and procedures. 9. Install a new A/C compressor. Refer to the Compressor Replacement procedure in the HVAC section of SI. 10. Install a new orifice tube for the front A/C system. Refer to the Expansion (Orifice) Tube Replacement procedure in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > Customer Interest: > 03-01-38-019A > Sep > 04 > A/C - Underhood Rattle Noise on Hard Acceleration > Page 11222 11. If the vehicle is a 2003 model year Chevrolet Express or GMC Savana van, the vehicle may require a new accumulator. Refer to Corporate Bulletin Number 03-01-38-016 for more information. This bulletin refers to an updated design accumulator that may improve the performance of the A/C system. 12. Install a new serpentine belt tensioner and serpentine belt if they have been damaged due to A/C system slugging or an A/C compressor seizure. The serpentine belt tensioner may have broken stop tabs and/or a missing front cap. 13. Verify proper operation of the A/C system. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-01-38-019A > Sep > 04 > A/C - Underhood Rattle Noise on Hard Acceleration Refrigerant Filter: All Technical Service Bulletins A/C - Underhood Rattle Noise on Hard Acceleration File In Section: 01 - HVAC Bulletin No.: 03-01-38~019A Date: September, 2004 TECHNICAL Subject: Underhood Rattle Noise Heard On Acceleration (Check A/C System Performance and Compressor Operation) Models: 2003-2004 Cadillac CTS 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 2002-2004 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2002-2004 GMC Denali, Denali XL, Savana, Sierra, Yukon, Yukon XL 2002-2004 Commercial Upfitter Chassis Vehicles with Air Conditioning (A/C) This bulletin is being revised to update the service procedure and parts information. Please discard Corporate Bulletin Number 03-01-38-019 (Section 01 - HVAC). Condition Some customers may comment about an underhood rattle noise heard on acceleration or a sudden loss of A/C system performance. Cause This condition may be caused by liquid slugging of the A/C compressor. This condition may cause an internal failure in the A/C compressor. The serpentine belt tensioner and serpentine belt may also be damaged. Correction Technicians are to check the A/C system performance and compressor operation using the following repair procedure: 1. Open the hood and inspect the A/C compressor for damage and to see if the compressor is seized. Verify that the serpentine belt is not damaged or missing. If the A/C compressor is seized, proceed to Step 5. 2. Perform the A/C System Performance test. Refer to the Heating, Ventilation and Air Conditioning (HVAC) section of SI. Correct any performance concerns or refrigerant leaks that are found. 3. Inspect the vehicle for other possible sources of A/C compressor noise or performance concerns. Refer to Corporate Bulletin Number 01-01-38-013 for more information. 4. After all other possible sources of A/C compressor noise or performance concerns have been eliminated, only then should the A/C compressor be replaced. 5. Remove the A/C compressor. Refer to the A/C Compressor Replacement procedure in the HVAC section of SI. 6. Inspect the transmission cooler lines for damage due to contact from the serpentine belt. Replace the transmission cooler lines if necessary. 7. Install an inline A/C system filter. Refer to Corporate Bulletin Number 01-01-38-006C for more information about A/C system flushing and filter installation procedures. An A/C system flush is not to be done unless prior authorization is given by the GM Area Service Manager (in Canada, the District Service Manager). 8. Install an A/C Suction Screen. Refer to Corporate Bulletin Number 01-01-39-003A for more information about A/C suction screen repair recommendations and procedures. 9. Install a new A/C compressor. Refer to the Compressor Replacement procedure in the HVAC section of SI. 10. Install a new orifice tube for the front A/C system. Refer to the Expansion (Orifice) Tube Replacement procedure in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-01-38-019A > Sep > 04 > A/C - Underhood Rattle Noise on Hard Acceleration > Page 11228 11. If the vehicle is a 2003 model year Chevrolet Express or GMC Savana van, the vehicle may require a new accumulator. Refer to Corporate Bulletin Number 03-01-38-016 for more information. This bulletin refers to an updated design accumulator that may improve the performance of the A/C system. 12. Install a new serpentine belt tensioner and serpentine belt if they have been damaged due to A/C system slugging or an A/C compressor seizure. The serpentine belt tensioner may have broken stop tabs and/or a missing front cap. 13. Verify proper operation of the A/C system. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11234 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11235 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11236 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11241 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11242 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11243 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11244 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11245 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11246 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 11251 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11257 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11258 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11259 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11264 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11265 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11266 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11267 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11268 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11269 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Filter: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 11274 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) Refrigerant Filter: Service and Repair A/C Refrigerant Filter Installation (C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C Refrigerant filter, AC P/N 15-1696 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. 2. Measure 50 mm (2 in) from the bend on the evaporator tube (2) near the expansion tube end and mark the location. 3. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs. 4. Using a tubing cutter, cut the marked section of the evaporator tube (2). 5. Remove the burrs from the evaporator tube (2). 6. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. 7. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 8. Install the ferrules (3) with the small end toward the nut (4). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11277 9. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 10. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 11. Remove the nuts (4) from the A/C refrigerant filter (1). 12. Coat the O-rings (2) with 525 viscosity refrigerant oil. 13. Install the O-rings (2) to the evaporator tube halves. 14. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fittings of the component using the J 39400-A. 17. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11278 Refrigerant Filter: Service and Repair A/C Refrigerant Filter Installation (C69) TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C refrigerant filter, AC P/N 15-1696 must be installed to the A/C evaporator tube (liquid line) between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. 2. Remove the evaporator tube (2) from the vehicle. 3. Measure 45 mm (1.75 in) from the bend on the condenser end of the evaporator tube (2) and mark the location. 4. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) towards the evaporator from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs. 5. Using a tubing cutter, cut the marked section of the evaporator tube (2). 6. Remove the burrs from the evaporator tube (2). 7. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: Do Not install the O-rings (2) in this step. 8. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 9. Install the ferrules (3) with the small end toward the nut (4). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11279 10. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 11. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 12. Remove the nuts (4) from the A/C refrigerant filter (1). 13. Coat the O-rings (2) with 525 viscosity refrigerant oil. 14. Install the O-rings (2) to the evaporator tube halves. 15. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11280 16. Install the evaporator tube (2) to the vehicle. 17. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 18. Leak test the fittings of the component using the J 39400-A. 19. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11281 Refrigerant Filter: Service and Repair A/C Refrigerant Filter Replacement (C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. IMPORTANT: The nuts (4) and the ferrules (3) will remain on the evaporator tube. Do not try to remove. 3. Remove the nuts (4) from the A/C refrigerant filter (1). 4. Remove the A/C refrigerant filter (3) from the evaporator tube (2). INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11282 1. Coat the O-rings (2) with 525 viscosity refrigerant oil. 2. Install the O-rings (2) to the evaporator tube. 3. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11283 4. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11284 Refrigerant Filter: Service and Repair A/C Refrigerant Filter Replacement (C69) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. 3. Remove the evaporator tube (2) from the vehicle. IMPORTANT: The nuts (4) and ferrules (3) will remain on the evaporator tube. Do not try to remove. 4. Remove the nuts (4) from the A/C refrigerant filter (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11285 5. Remove the A/C refrigerant filter (3) from the evaporator tube (2). INSTALLATION PROCEDURE 1. Lubricate the O-rings (2) with 525 viscosity refrigerant oil. 2. Install the O-rings (2) to the evaporator tube. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11286 3. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11287 5. Install the evaporator tube (2) to the vehicle. 6. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fitting(s) of the repaired or reinstalled component using the J39400-A. 8. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11288 Refrigerant Filter: Service and Repair A/C Refrigerant Filter Installation (C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C Refrigerant filter, AC P/N 15-1696 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. 2. Measure 50 mm (2 in) from the bend on the evaporator tube (2) near the expansion tube end and mark the location. 3. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs. 4. Using a tubing cutter, cut the marked section of the evaporator tube (2). 5. Remove the burrs from the evaporator tube (2). 6. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. 7. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 8. Install the ferrules (3) with the small end toward the nut (4). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11289 9. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 10. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 11. Remove the nuts (4) from the A/C refrigerant filter (1). 12. Coat the O-rings (2) with 525 viscosity refrigerant oil. 13. Install the O-rings (2) to the evaporator tube halves. 14. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fittings of the component using the J 39400-A. 17. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes A/C Refrigerant Filter Installation (C69) TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11290 J 39400-A Halogen Leak Detector IMPORTANT: The A/C refrigerant filter, AC P/N 15-1696 must be installed to the A/C evaporator tube (liquid line) between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. 2. Remove the evaporator tube (2) from the vehicle. 3. Measure 45 mm (1.75 in) from the bend on the condenser end of the evaporator tube (2) and mark the location. 4. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) towards the evaporator from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs. 5. Using a tubing cutter, cut the marked section of the evaporator tube (2). 6. Remove the burrs from the evaporator tube (2). 7. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: Do Not install the O-rings (2) in this step. 8. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 9. Install the ferrules (3) with the small end toward the nut (4). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11291 10. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 11. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 12. Remove the nuts (4) from the A/C refrigerant filter (1). 13. Coat the O-rings (2) with 525 viscosity refrigerant oil. 14. Install the O-rings (2) to the evaporator tube halves. 15. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11292 16. Install the evaporator tube (2) to the vehicle. 17. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 18. Leak test the fittings of the component using the J 39400-A. 19. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes A/C Refrigerant Filter Replacement (C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. IMPORTANT: The nuts (4) and the ferrules (3) will remain on the evaporator tube. Do not try to remove. 3. Remove the nuts (4) from the A/C refrigerant filter (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11293 4. Remove the A/C refrigerant filter (3) from the evaporator tube (2). INSTALLATION PROCEDURE 1. Coat the O-rings (2) with 525 viscosity refrigerant oil. 2. Install the O-rings (2) to the evaporator tube. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11294 3. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes A/C Refrigerant Filter Replacement (C69) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. 3. Remove the evaporator tube (2) from the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11295 IMPORTANT: The nuts (4) and ferrules (3) will remain on the evaporator tube. Do not try to remove. 4. Remove the nuts (4) from the A/C refrigerant filter (1). 5. Remove the A/C refrigerant filter (3) from the evaporator tube (2). INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11296 1. Lubricate the O-rings (2) with 525 viscosity refrigerant oil. 2. Install the O-rings (2) to the evaporator tube. 3. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11297 4. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 5. Install the evaporator tube (2) to the vehicle. 6. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fitting(s) of the repaired or reinstalled component using the J39400-A. 8. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Computers and Controls Systems. "For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Suction Screen Installation TOOL REQUIRED J 44551 Suction Screen Kit IMPORTANT: Suction screens are intended to be installed in the suction hose after a major compressor failure. The suction screens are available in 3 different sizes. 1. Insert the J 44551-6 sizing tool into the suction hose to select the correct size suction screen. 2. Insert the suction screen into the compressor end of the suction hose. 3. Install the correct mandrel to the J 44551-5. 4. Install the J 44551-5 screen installation tool over the end of the suction hose and the suction screen. IMPORTANT: Correct placement of the J 44551-5 is critical. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > A/C Refrigerant Filter Installation (C60) > Page 11298 5. Tighten the forcing screw of the J 44551-5. The suction screen is fully installed when the screen is flush with the end of the suction hose fitting. 6. Remove the J 44551-5 suction screen tool from the suction hose. IMPORTANT: After a major compressor failure an A/C refrigerant filter should also be installed. 7. Install an A/C refrigerant filter. 8. Install the J 44551-1 Suction Screen Notification label. Suction Screen Replacement TOOLS REQUIRED - J 42220 Universal Leak Detection Lamp - J 44551 Suction Screen Kit REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the A/C compressor hose assembly bolt. 3. Separate the A/C compressor hose assembly from the A/C compressor. IMPORTANT: The suction screens are available in 3 different sizes. 4. Select the proper size removal tool from the J 44551. 5. Remove the suction screen using the J 44551-31 suction screen removal tool. - Thread the forcing screw into the suction screen. - Tighten the nut on the forcing screw to remove the suction screen. INSTALLATION PROCEDURE 1. Insert the J 44551-6 sizing tool into the suction hose to select the correct size suction screen. 2. Insert the suction screen into the suction hose. 3. Install the J 44551-3 mandrel to the J 44551-5. 4. Install the J 44551-5 suction screen installation tool over the end of the suction hose and the suction screen. IMPORTANT: Correct placement of the J 44551-5 is critical. 5. Tighten the forcing screw of the J 44551-5. The suction screen is fully installed when the screen is flush with the end of the suction hose. 6. Remove the J 44551-5 suction screen tool from the suction hose. 7. Replace the seal washers. Refer to Compressor Sealing Washers Replacement. 8. Install the A/C compressor hose assembly to the A/C compressor. NOTE: Refer to Fastener Notice in Service Precautions. 9. Install the A/C compressor hose assembly bolt. Tighten Tighten the bolt to 34 N.m (25 lb ft). 10. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 11. Leak test the fittings of the component using the J 42220. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications If the refrigerant oil was removed from the A/C system during the recovery process or during the component replacement, the refrigerant oil must be replenished. Add the refrigerant oil as indicated. If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. Accumulator ......................................................................................................................................... .......................................................................... 60 ml Compressor .................................................... .............................................................................................................................................................. .. 60 ml Condenser .............................................................................................................................. ........................................................................................ 30 ml Evaporator ........................................ .............................................................................................................................................................. ................ 90 ml Evaporator (Rear) ..................................................................................................... ..................................................................................................... 90 ml Abrupt Loss .......................... .............................................................................................................................................................. ............................ 90 ml NOTE: Replacement compressors do not have any oil in the compressor. Add the correct amount of oil to the replacement compressor before replacement. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 11305 Refrigerant Oil: Fluid Type Specifications Internal Lubricant ............................................................................................................................. Poly-Alkaline Glycol (PAG) Synthetic Refrigerant Oil Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Diagnose A/C Low Pressure Switch Low Pressure Sensor / Switch: Technical Service Bulletins Air Conditioning - Diagnose A/C Low Pressure Switch INFORMATION Bulletin No.: 04-01-38-010A Date: January 21, 2010 Subject: Diagnostic Information to Accurately Diagnose A/C Low Pressure Switch Using Kent Moore Special Tool GE-47742 Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2007 Chevrolet Silverado 2000-2006 Chevrolet Suburban, Tahoe 2002-2007 Chevrolet Avalanche 1999-2007 GMC Sierra 2000-2006 GMC Yukon, Yukon XL 2001-2006 GMC Yukon Denali XL 2001-2007 GMC Sierra Denali, Yukon Denali XL 2003-2008 HUMMER H2 with Air Conditioning Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 04-01-38-010 (Section 01 - HVAC). Currently, technicians cannot accurately determine the air conditioning (A/C) low pressure switch open/close pressure point by measuring pressure at the low side service port. This is because the evaporator is between the low side service port and the A/C low pressure switch. Correlating pressures measured at the low side service port to actual pressures at the A/C low pressure switch port is difficult because of the multiple variables that impact pressure drop across the evaporator. Providing a pressure range that would take into account all these variables would result in a pressure range that would be too broad to be useful for diagnostic purposes. Kent Moore special tool GE-47742 will allow technicians to monitor the actual pressures at which the A/C low pressure switch opens and closes under actual operating conditions. Technicians are to use the following steps to install and use Kent Moore special tool GE-47742 to measure A/C low pressure switch opening and closing pressures: 1. Disconnect the wire harness from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Install the A/C low pressure switch, using the threaded port with an O-ring, onto special tool GE-47742. 4. Install special tool GE-47742, with the A/C low pressure switch attached, onto the accumulator. Important Removing the seal from the A/C low pressure switch wire harness connector is required. Failure to remove the seal before plugging it into the switch will lead to misdiagnosis. The "plunger effect" of plugging the connector with a seal into the A/C low pressure switch induces a pressure on the back side of the switch. This pressure will skew the opening/closing characteristics of the switch 34-69 kPa (5-10 psi) until the pressure bleeds off. The time required for the connection induced pressure to bleed off can be 20 minutes or longer. 5. Remove the seal from the A/C low pressure switch wire harness connector. 6. Connect the wire harness, without the seal, to the A/C low pressure switch. 7. Connect the low side service hose from the ACR2000(R) or GE-48800 to the service port on special tool GE-47742. 8. Connect a Tech2(R) to the vehicle. 9. Start the vehicle and maintain an engine speed of 1500 RPM. Set the HVAC controls as follows: - Set the A/C control switch to ON. - Set the mode control switch to A/C and engage recirculation mode. - Set the blower motor speed to LOW. - Set the temperature control to full cold. - Set the auxiliary blower motor speed to LOW. If equipped. - Set the auxiliary temperature control to full cold. If equipped. - The vehicle must be operating with no sun load (in the shade). 10. Use the Tech2(R) to determine the A/C low pressure switch status and the ACR2000(R) or GE-48800 to determine the A/C low side pressure. Simultaneously monitor the switch status and the pressure at which the A/C low pressure switch opens and closes. The Tech2(R) will display switch status as "Normal" for Closed and "Low Pressure" for Open. A properly operating switch should open between 138-172 kPa (20-25 psi) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Diagnose A/C Low Pressure Switch > Page 11311 and close between 275-317 kPa (40-46 psi). 11. Remove special tool GE-47742 after diagnosis is complete. 12. Install a new O-ring on the A/C low pressure switch port on the accumulator. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 13. Install the A/C low pressure switch onto the accumulator. Tighten Tighten the A/C low pressure switch to 6 Nm (44 lb in). Important Remember to install the seal back onto the A/C low pressure switch wire harness connector. Failure to replace the seal could result in terminal corrosion. 14. Reconnect the wire harness to the A/C low pressure switch. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 11319 Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover from the underhood convenience center (1). 2. Remove the compressor relay (2). INSTALLATION PROCEDURE 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 04-01-39-007 > Jun > 04 > A/C - Loss of Mode or Temperature Control Control Module HVAC: Customer Interest A/C - Loss of Mode or Temperature Control Bulletin No.: 04-01-39-007 Date: June 17, 2004 TECHNICAL Subject: Loss Of HVAC System Mode and/or Temperature Control (Replace HVAC Control Module) Models: 2002 Cadillac Escalade, Escalade EXT 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalanche 1999-2002 GMC Denali, Sierra, Yukon, Yukon XL 2001 GMC Sierra C3 2002 GMC Sierra Denali with Automatic HVAC System (RPO C68) Condition Some customers may comment that they cannot control the HVAC system modes and/or the temperature. These concerns may be intermittent. Cause An HVAC control module logic lock-up may be the cause of these conditions. Correction Important: Prior to replacing the HVAC control head, review Corporate Bulletin Number 01-01-39-007. Replace the HVAC control module. Refer to the HVAC Control Module Replacement procedure in the HVAC System - Automatic sub-section of the Service Manual. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 04-01-39-007 > Jun > 04 > A/C - Loss of Mode or Temperature Control > Page 11328 Part Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 04-01-39-007 > Jun > 04 > A/C - Loss of Mode or Temperature Control Control Module HVAC: All Technical Service Bulletins A/C - Loss of Mode or Temperature Control Bulletin No.: 04-01-39-007 Date: June 17, 2004 TECHNICAL Subject: Loss Of HVAC System Mode and/or Temperature Control (Replace HVAC Control Module) Models: 2002 Cadillac Escalade, Escalade EXT 1999-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalanche 1999-2002 GMC Denali, Sierra, Yukon, Yukon XL 2001 GMC Sierra C3 2002 GMC Sierra Denali with Automatic HVAC System (RPO C68) Condition Some customers may comment that they cannot control the HVAC system modes and/or the temperature. These concerns may be intermittent. Cause An HVAC control module logic lock-up may be the cause of these conditions. Correction Important: Prior to replacing the HVAC control head, review Corporate Bulletin Number 01-01-39-007. Replace the HVAC control module. Refer to the HVAC Control Module Replacement procedure in the HVAC System - Automatic sub-section of the Service Manual. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 04-01-39-007 > Jun > 04 > A/C - Loss of Mode or Temperature Control > Page 11334 Part Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 11335 Blower Motor Control Processor - Auxiliary (Tahoe/Yukon) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic Control Module HVAC: Service and Repair HVAC System - Automatic HVAC Control Module Replacement REMOVAL PROCEDURE 1. Remove the instrument panel accessory trim plate. 2. Remove the screws from the HVAC control module. 3. Depress the control assembly retaining tabs and remove the HVAC control module from the instrument panel. 4. Disconnect the electrical connectors from the HVAC control module. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the HVAC control module. 2. Install the HVAC control module into the instrument panel, ensuring that the HVAC control module retaining tabs lock into place. NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Install the screws to the HVAC control module. Tighten Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11338 Tighten the screws to 1.9 N.m (17 lb in). 4. Install the instrument panel accessory trim plate. Important: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. 5. Start the vehicle and let run for one minute. HVAC Control Module Replacement - Auxiliary REMOVAL PROCEDURE 1. Separate the front of the console (1) from the headliner by pushing forward and pulling down in front. 2. Remove the HVAC control assembly (2) by releasing the tabs at the rear of the control. Push out from the back through the console. 3. Disconnect the electrical connector (3). INSTALLATION PROCEDURE 1. Connect the electrical connector (3). 2. Install the HVAC control assembly (2) to the console (1). 3. Install the console to the headliner. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11339 Control Module HVAC: Service and Repair HVAC System - Manual HVAC CONTROL PROCESSOR REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the auxiliary rear HVAC control assembly. 2. Remove the auxiliary HVAC control processor (2) from the bracket (3). 3. Remove the cover from the auxiliary HVAC control processor (2). 4. Remove the auxiliary HVAC control processor (2) from the box (1). INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11340 1. Install the auxiliary HVAC control processor (2) to the box. (1) 2. Install the cover to the auxiliary HVAC control processor (2). 3. Install the auxiliary HVAC control processor (2) to the bracket (3). 4. Install the auxiliary rear HVAC control assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations System Relay: Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations > Page 11344 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper Air Temperature Sensor - Upper Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper > Page 11351 Air Temperature Sensor - Lower Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper > Page 11352 Air Temperature Sensor - Ambient Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper > Page 11353 Air Temperature Sensor - Lower Auxiliary Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper > Page 11354 Air Temperature Sensor Assembly - Inside (Over Head) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 11355 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL PROCEDURE 1. Remove the Park/Turn Signal. 2. Disconnect the electrical connector from the ambient air temperature sensor (3). 3. Remove the ambient air temperature sensor (3). INSTALLATION PROCEDURE 1. Install the ambient air temperature sensor (3). 2. Connect the electrical connector to the ambient air temperature sensor (3). 3. Install the Park/Turn Signal. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams HVAC Blower Motor Control Switch - C2 (Part Of HVAC Control Assembly) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Page 11359 Blower Motor Switch: Service and Repair BLOWER MOTOR SWITCH REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Separate the front of the console (1) from the headliner. 2. Remove the blower motor switch (2) by releasing the tabs at the rear of the switch housing. 3. Disconnect the electrical connector (3). INSTALLATION PROCEDURE 1. Connect the electrical connector (3). 2. Install the blower motor switch (2) to the switch housing. 3. Install the console (1) to the headliner. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair Cabin Temperature Sensor / Switch: Service and Repair INSIDE AIR TEMPERATURE SENSOR REPLACEMENT (OVERHEAD) REMOVAL PROCEDURE 1. Remove the left windshield garnish molding. 2. Remove the left center pillar assist handle. 3. Remove the left center pillar garnish molding. 4. Remove the left sunshade. 5. Remove the retaining screws from the headliner. 6. Gently pull down the headliner. 7. Remove the inside air temperature sensor from the headliner. 8. Disconnect the electrical connector from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Page 11363 1. Install the inside air temperature sensor to the headliner. 2. Connect the electrical connector to the inside air temperature sensor. 3. Install the screws to the headliner. 4. Install the left sunshade. 5. Install the left center pillar garnish molding. 6. Install the left center assist handle. 7. Install the left windshield garnish molding. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Air Temperature Sensor-Upper Auxiliary Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Air Temperature Sensor-Upper Auxiliary > Page 11368 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper REMOVAL PROCEDURE 1. Remove the radio. 2. Disconnect the electrical connector from the upper duct air temperature sensor. 3. Remove the upper duct air temperature sensor from the air duct by prying out of the duct. INSTALLATION PROCEDURE 1. Install the upper duct air temperature sensor to the air duct. 2. Connect the electrical connector to the upper duct air temperature sensor. 3. Install the radio. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper > Page 11371 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper Auxiliary REMOVAL PROCEDURE 1. Remove the right side C-Pillar Trim Panel. 2. Disconnect the electrical connector from the rear upper A/C temperature sensor (11). 3. Remove the rear upper A/C temperature sensor (11) from the air distribution duct. INSTALLATION PROCEDURE 1. Install the rear upper A/C temperature sensor (11) to the air distribution duct. 2. Connect the electrical connector to the rear upper A/C temperature sensor (11). 3. Install the right side C-Pillar Trim Panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper > Page 11372 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower REMOVAL PROCEDURE 1. Remove the lower duct air temperature sensor (3) and wiring harness assembly from the floor air outlet (2). 2. Disconnect the electrical connector from the lower duct air temperature sensor (3). INSTALLATION PROCEDURE 1. Connect the lower duct air temperature sensor (3) to the electrical connector. 2. Install the lower duct air temperature sensor (3) and wiring harness assembly to the floor air outlet (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper > Page 11373 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Auxiliary REMOVAL PROCEDURE 1. Remove the right side C-Pillar Trim Panel. 2. Disconnect the electrical connector from the auxiliary lower A/C temperature sensor (10). 3. Remove the auxiliary lower A/C temperature sensor (10) from the air distribution duct. INSTALLATION PROCEDURE 1. Install the rear lower A/C temperature sensor (10) to the air distribution duct. 2. Connect the electrical connector to the rear lower A/C temperature sensor (10). 3. Install the right side C-Pillar Trim Panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Diagnose A/C Low Pressure Switch Low Pressure Sensor / Switch: Technical Service Bulletins Air Conditioning - Diagnose A/C Low Pressure Switch INFORMATION Bulletin No.: 04-01-38-010A Date: January 21, 2010 Subject: Diagnostic Information to Accurately Diagnose A/C Low Pressure Switch Using Kent Moore Special Tool GE-47742 Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2007 Chevrolet Silverado 2000-2006 Chevrolet Suburban, Tahoe 2002-2007 Chevrolet Avalanche 1999-2007 GMC Sierra 2000-2006 GMC Yukon, Yukon XL 2001-2006 GMC Yukon Denali XL 2001-2007 GMC Sierra Denali, Yukon Denali XL 2003-2008 HUMMER H2 with Air Conditioning Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 04-01-38-010 (Section 01 - HVAC). Currently, technicians cannot accurately determine the air conditioning (A/C) low pressure switch open/close pressure point by measuring pressure at the low side service port. This is because the evaporator is between the low side service port and the A/C low pressure switch. Correlating pressures measured at the low side service port to actual pressures at the A/C low pressure switch port is difficult because of the multiple variables that impact pressure drop across the evaporator. Providing a pressure range that would take into account all these variables would result in a pressure range that would be too broad to be useful for diagnostic purposes. Kent Moore special tool GE-47742 will allow technicians to monitor the actual pressures at which the A/C low pressure switch opens and closes under actual operating conditions. Technicians are to use the following steps to install and use Kent Moore special tool GE-47742 to measure A/C low pressure switch opening and closing pressures: 1. Disconnect the wire harness from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Install the A/C low pressure switch, using the threaded port with an O-ring, onto special tool GE-47742. 4. Install special tool GE-47742, with the A/C low pressure switch attached, onto the accumulator. Important Removing the seal from the A/C low pressure switch wire harness connector is required. Failure to remove the seal before plugging it into the switch will lead to misdiagnosis. The "plunger effect" of plugging the connector with a seal into the A/C low pressure switch induces a pressure on the back side of the switch. This pressure will skew the opening/closing characteristics of the switch 34-69 kPa (5-10 psi) until the pressure bleeds off. The time required for the connection induced pressure to bleed off can be 20 minutes or longer. 5. Remove the seal from the A/C low pressure switch wire harness connector. 6. Connect the wire harness, without the seal, to the A/C low pressure switch. 7. Connect the low side service hose from the ACR2000(R) or GE-48800 to the service port on special tool GE-47742. 8. Connect a Tech2(R) to the vehicle. 9. Start the vehicle and maintain an engine speed of 1500 RPM. Set the HVAC controls as follows: - Set the A/C control switch to ON. - Set the mode control switch to A/C and engage recirculation mode. - Set the blower motor speed to LOW. - Set the temperature control to full cold. - Set the auxiliary blower motor speed to LOW. If equipped. - Set the auxiliary temperature control to full cold. If equipped. - The vehicle must be operating with no sun load (in the shade). 10. Use the Tech2(R) to determine the A/C low pressure switch status and the ACR2000(R) or GE-48800 to determine the A/C low side pressure. Simultaneously monitor the switch status and the pressure at which the A/C low pressure switch opens and closes. The Tech2(R) will display switch status as "Normal" for Closed and "Low Pressure" for Open. A properly operating switch should open between 138-172 kPa (20-25 psi) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Diagnose A/C Low Pressure Switch > Page 11379 and close between 275-317 kPa (40-46 psi). 11. Remove special tool GE-47742 after diagnosis is complete. 12. Install a new O-ring on the A/C low pressure switch port on the accumulator. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 13. Install the A/C low pressure switch onto the accumulator. Tighten Tighten the A/C low pressure switch to 6 Nm (44 lb in). Important Remember to install the seal back onto the A/C low pressure switch wire harness connector. Failure to replace the seal could result in terminal corrosion. 14. Reconnect the wire harness to the A/C low pressure switch. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 11383 Sunload Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 11384 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel upper trim pad. 2. Turn the Sun Load Sensor (2)1/4 turn and remove it from the upper trim pad. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the sun load sensor (2) to the upper trim pad turning it 1/4 turn to secure it in place. 3. Install the instrument panel upper trim pad. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 11388 Sunload Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 11389 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel upper trim pad. 2. Turn the Sun Load Sensor (2)1/4 turn and remove it from the upper trim pad. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the sun load sensor (2) to the upper trim pad turning it 1/4 turn to secure it in place. 3. Install the instrument panel upper trim pad. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Locations System Relay: Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Locations > Page 11393 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System Accident With Frontal Air Bag Deployment CAUTION: Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. After a collision involving frontal air bag deployment, replace the following components. ^ Inflatable restraint electronic frontal sensor (EFS) ^ Inflatable restraint front end discriminating sensor ^ Inflatable restraint IP module ^ Inflatable restraint sensing and diagnostic module (5DM) ^ Inflatable restraint steering wheel module Perform additional inspections on the following components. ^ Steering wheel module coil and coil wiring pigtail - Inspect for melting, scorching, or other damage due to excessive heat. ^ Mounting points and mounting hardware for the EFS, front end discriminating sensor, IP module, steering wheel module, and SDM- Inspect for damage and repair or replace each component as needed. Accident With or Without Air Bag Deployment CAUTION: ^ Proper operation of the Supplemental inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment at the air bag(s) in a frontal collision or deployment at the air bag(s) for conditions less severe than intended. ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than intended. After any collision, inspect the following components as indicated. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. ^ Steering column-Perform the steering column accident damage checking procedures. Refer to Steering Column Accident Damage Inspection Off Vehicle in Steering Wheel and Column Standard or Steering Column Accident Damage Inspection - Off Vehicle in Steering Wheel and Column - Tilt. ^ I/P Knee Bolsters and Mounting Points-Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. ^ I/P brackets, braces, etc.- Inspect for bending, twisting, buckling, or any other type of damage. ^ Seat Belts-Perform the seat belt operational and functional checks Refer to Operational and Functional Checks in Seat Belts. See: Seat Belt Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Operational and Functional Checks ^ Seats and Seat Mounting Points-Inspect for bending, twisting, buckling, or any other type of damage. Accident With Side Air Bag Deployment After a collision involving side air bag deployment, replace the following components. ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Inflatable restraint side impact module, on side of impact ^ Inflatable restraint side impact sensor (SIS), on side of impact Perform additional inspections on the following components. ^ Mounting points and mounting hardware for the side impact module and SDM - Inspect for any damage and repair or replace each component as needed. ^ Inspect the components indicated above in Accident With or Without Air Bag Deployment. Accident With/Without Air Bag Deployment REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION ACCIDENT WITH OR WITHOUT AIR BAG DEPLOYMENT - COMPONENT INSPECTIONS CAUTION: Proper operation of the SIR sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment in a collision or deployment for conditions less severe than intended. After any collision, inspect the following components as indicated. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. Steering column-Perform the steering column accident damage checking procedures. Refer to Steering Column Accident Damage Inspection in Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 11399 Steering Wheel and Column. - I/P Knee Bolsters and Mounting Points-Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. - I/P brackets, braces, etc.-Inspect for bending, twisting, buckling, or any other type of damage. - Seat Belts-Perform the seat belt operational and functional checks. Refer to Operational and Functional Checks in Seat Belts. - Seats and Seat Mounting Points-Inspect for bending, twisting, buckling, or any other type of damage. ACCIDENT WITH FRONTAL AIR BAG DEPLOYMENT - COMPONENT REPLACEMENT AND INSPECTIONS After a collision involving frontal air bag deployment, replace the following components. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. Inflatable restraint front end sensors - Inflatable restraint IP module - Inflatable restraint sensing and diagnostic module (SDM) - Inflatable restraint side impact module, if deployed - Inflatable restraint steering wheel module After a collision involving frontal air bag deployment, perform the following inspections. Inspect the steering wheel module coil and coil wiring pigtail for melting, scorching, or other damage due to excessive heat. - Inspect the passenger presence system (PPS) for damage to the wiring or pressure system. Perform these component inspections in addition to the inspections indicated above in Accident With or Without Air Bag Deployment. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. ACCIDENT WITH SIDE AIR BAG DEPLOYMENT - COMPONENT REPLACEMENT AND INSPECTIONS After a collision involving side air bag deployment, replace the following components. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. Inflatable restraint sensing and diagnostic module (SDM) - Inflatable restraint side impact module, on side of impact - Inflatable restraint side impact sensor (SIS), on side of impact After a collision involving side air bag deployment, inspect the passenger presence system (PPS) for damage to the wiring or pressure system. Perform this component inspection in addition to the inspections indicated above in Accident With or Without Air Bag Deployment. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. SENSOR REPLACEMENT GUIDELINES The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has an SIR sensor mounted forward of the radiator, it must be replaced. Replace the sensor whether or not the air bags have deployed. - Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. SIR Sensor Replacement Guidelines The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has an SIR sensor mounted forward of the radiator, it must be replaced ^ Replace the sensor whether or not the air bags have deployed. ^ Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 11400 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION CAUTION: Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: - Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. - Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. - Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. - Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 11401 Repairs and Inspections Required After a Collision: Service and Repair Steering Column Steering Column Accident Damage Inspection - Off Vehicle - Vehicles involved in accidents resulting in frame damage, major body or sheet metal damage, or where the steering column has been impacted, or where supplemental inflatable restraint systems deployed may also have a damaged or misaligned steering column. - Inspect the capsules on the steering column bracket assembly. All capsules must be securely seated in the bracket slots and checked for any loose conditions when pushed or pulled by hand. If not, the bracket should be replaced if bolted to the jacket assembly. If the bracket is welded to the jacket assembly replace the jacket assembly. - Inspect for jacket assembly collapse by measuring the distance from the lower edge of the upper jacket to a defined point on the lower jacket. If measured dimensions are not within specifications, a new jacket must be installed. - Inflatable restraint coil assembly must be removed from the steering column and allowed to hang freely before shaft is rotated. Failure to do so could damage coil assembly. - Visually inspect steering shaft for sheared injected plastic. If steering shaft shows sheared plastic, a new steering shaft must be installed. - Any frame damage that could cause a bent steering shaft must have the steering shaft runout checked in the following manner. Using a dial indicator at the lower end of the steering shaft, have the steering wheel rotated. Runout must not exceed 1.60 MM. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the fuse block. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Disconnect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 7. Access the IP module yellow 2-way connector (1) located behind the IP module (2) by removing the upper IP trim panel. Refer to Trim Pad Replacement - IP Upper in Instrument Panel, Gauges and Warning Indicators. 8. Remove the CPA from the IP module yellow 2-way connector (1) located behind the IP module (2). 9. Disconnect the IP module yellow 2-way connector (1) located behind the IP module (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 11407 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the IP module yellow 2-way connector (1) located behind the main IP support. 3. Install the CPA to the IP module yellow 2-way connector (1) located behind the main IP support. 4. Connect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 5. Install the CPA (1) to the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Install the AIR BAG Fuse to the fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - SIR if the AIR BAG indicator does not operate as described. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Customer Interest for Air Bag: > 05-08-110-003 > Mar > 05 > Air Bag System - Passenger Air Bag Discolored Air Bag: Customer Interest Air Bag System - Passenger Air Bag Discolored Bulletin No.: 05-08-110-003 Date: March 24, 2005 INFORMATION Subject: Information on Cleaning Discolored Passenger Side Air Bag Cover Models: 2000-2005 Chevrolet and GMC Full Size Pickups and Utilities with Passenger Side Air Bag The passenger side air bag module cover may be discoloring. DO NOT replace the air bag module for discoloring concerns. The discoloring is a salt that is formed on the air bag cover surface as a result of a chemical reaction between the polyester cover material and gases originating from urethane components in the vehicle. Clean the air bag cover with a nonabrasive liquid soap (such as liquid dish soap or liquid hand soap) and warm water solution. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 05-08-110-003 > Mar > 05 > Air Bag System - Passenger Air Bag Discolored Air Bag: All Technical Service Bulletins Air Bag System - Passenger Air Bag Discolored Bulletin No.: 05-08-110-003 Date: March 24, 2005 INFORMATION Subject: Information on Cleaning Discolored Passenger Side Air Bag Cover Models: 2000-2005 Chevrolet and GMC Full Size Pickups and Utilities with Passenger Side Air Bag The passenger side air bag module cover may be discoloring. DO NOT replace the air bag module for discoloring concerns. The discoloring is a salt that is formed on the air bag cover surface as a result of a chemical reaction between the polyester cover material and gases originating from urethane components in the vehicle. Clean the air bag cover with a nonabrasive liquid soap (such as liquid dish soap or liquid hand soap) and warm water solution. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 11421 Fastener Tightening Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations Air Bag: Component Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 11424 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 11425 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 11426 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 11427 Air Bag: Connector Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 11428 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 11429 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 11430 Air Bag: Harness Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 11431 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 11432 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Inflatable Restraint Instrument Panel Module Inflatable Restraint IP Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Technician Safety Information Air Bag: Technician Safety Information Inflator Module Precautions CAUTION: When carrying a live inflator module, make sure the bag opening is pointed away from you. This minimizes the chance of injury in the case of an accidental deployment. Never carry the inflator module by the wires. Never carry the inflator module by the connector on the underside of the module. Make sure that the bag and trim cover are facing up whenever you place a live inflator module on any surface. This is necessary to provide a free space for the bag to expand in the unlikely event of accidental deployment. Never rest the steering column assembly on the steering wheel with the inflator module face down, and the column vertical. This may result in personal injury. Inflator Module Disposal CAUTION: When you are deploying an inflator module for disposal perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Technician Safety Information > Page 11437 Air Bag: Vehicle Damage Warnings Inflator Module Precautions CAUTION: When carrying a live inflator module, make sure the bag opening is pointed away from you. This minimizes the chance of injury in the case of an accidental deployment. Never carry the inflator module by the wires. Never carry the inflator module by the connector on the underside of the module. Make sure that the bag and trim cover are facing up whenever you place a live inflator module on any surface. This is necessary to provide a free space for the bag to expand in the unlikely event of accidental deployment. Never rest the steering column assembly on the steering wheel with the inflator module face down, and the column vertical. This may result in personal injury. Inflator Module Disposal CAUTION: When you are deploying an inflator module for disposal perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Page 11438 Air Bag: Description and Operation INFLATOR MODULES The inflator modules contain a housing, inflatable air bag, initiating device, canister of gas generating material and, in some cases, stored compressed gas. The initiator is part of the inflator module deployment loop. When the vehicle is involved in a collision of sufficient force, the SDM will cause current to flow through the deployment loops to the initiator. Current passing through the initiator ignites the material in the canister producing a rapid generation of gas and the release of compressed gas, if present. The gas produced from this reaction rapidly inflates the air bag. Once the air bag is inflated it quickly deflates through the air bag vent holes. Each inflator module is equipped with a shorting bar located on the connector of the module. The shorting bar shorts the inflator module deployment loop circuitry to prevent unwanted deployment of the air bag when it is disconnected. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures Air Bag: Service and Repair Deployment Procedures General Information Inflator modules can be deployed inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation. Deployment Outside Vehicle Deploy inflator modules outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: ^ Using the SIR diagnostics, you determine that the inflator module is malfunctioning. ^ The inflator module is cosmetically damaged (scratched or ripped). ^ The inflator module pigtail (if equipped) is damaged. ^ The inflator module connector is damaged. ^ The inflator module connector terminals are damaged. Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. CAUTION: Refer to SIR Inflator Module Disposal Caution in Service Precautions. TOOLS REQUIRED ^ J 38826 SIR Deployment Harness ^ J 39401-B SIR Deployment Fixture ^ An appropriate pigtail adaptor 1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove the inflator module. CAUTION: Refer to SIR Inflator Module Handling and Storage Caution in Service Precautions. 5. Place the inflator module with the vinyl trim cover facing up and away from the surface on a work bench, floor or deployment fixture. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11441 6. Clear an area on the floor approximately 1.85 m (6 ft) in diameter for deployment of the inflator module. If possible, use a paved, outdoor location free of activity. Otherwise, use an area free of activity on the shop floor. Make sure you have sufficient ventilation. 7. Make sure no loose or flammable objects are in the area. 8. When deploying a steering wheel module, place the steering wheel module in the center of the cleared area. 9. When deploying an IP module refer to the following instructions: ^ Place the J 39401-B (2) in the center of the cleared area. ^ Fill the deployment fixture (2) with water or sand. ^ Mount the IP module (1) in the deployment fixture (2) with the vinyl/plastic trim facing up. ^ To mount, use 4 M 6 bolts (6), nuts (8), and washers (7) to properly secure the IP module (1) to the deployment fixture (2). ^ Tighten all fasteners prior to deployment. 10. When deploying a side impact module, refer to the following instructions: ^ Place the J 39401-B SIR deployment fixture (3) in the center of the cleared area. ^ Fill the deployment fixture (3) with water or sand. ^ Mount the side impact module (1) in the deployment fixture (3) with the vinyl/plastic trim facing up. ^ Adjust and secure the J 39401-B arms (4) to the deployment fixture (3). ^ To mount, use 2 M 6 x 1.0 nuts (2) with washers to secure the side impact module (1) to the deployment fixture arms (4). ^ Tighten all fasteners prior to deployment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11442 11. Inspect the J 38826 SIR deployment harness and the appropriate pigtail adapter for damage. Replace as needed. 12. Short the 2 SIR deployment harness (1) leads together using one banana plug seated into the other. 13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 14. Extend the SIR deployment harness and adapter to full length from the deployment fixture. 15. Connect the inflator module (1) to the adapter (2) on the SIR deployment harness (3). IMPORTANT: ^ The rapid expansion of gas involved with deploying an inflator module is very loud. Notify all people in the immediate area that an inflator module will be deployed. ^ When the inflator module deploys, the deployment fixture may jump vertically. This is a normal reaction of the inflator module due to the force of the rapid expansion of gas inside the inflator module. 16. Clear the area of people. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11443 17. Separate the 2 banana plugs on the SIR deployment harness. 18. Place a 12 V minimum/2 A minimum power source (i.e. vehicle battery) near the shorted end of the SIR deployment harness. 19. Connect the SIR deployment harness wires to the power source. Inflator module deployment will occur when contact is made. 20. Disconnect the SIR deployment harness from the power source 21. Seat 1 banana plug into the other in order to short the deployment harness leads. CAUTION: Refer to SIR Deployed Inflator Modules Are Hot Caution in Service Precautions. 22. If the inflator module did not deploy disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group for further assistance. Otherwise, proceed to the following steps. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11444 23. Put on a pair of shop gloves. 24. Disconnect the pigtail adapter from the inflator module as soon as possible. 25. Dispose of the deployed inflator module through normal refuse channels. 26. Wash hands with a mild soap. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11445 Air Bag: Service and Repair Inflator Module Handling/Shipping/Scrapping Shipping/Scrapping Procedures For Live (Undeployed) Inflator Modules CAUTION: Refer to SIR Inflator Module Handling and Storage Caution in Service Precautions. LIVE (UNDEPLOYED) INFLATOR MODULES Use special care when handling or storing live (undeployed) inflator modules. Inflator module deployment produces a rapid generation of gas. This may cause the inflator module, or an object in front of the inflator module, to project through the air in the event of an unlikely deployment. SCRAPPING PROCEDURES During the course of a vehicle's useful life, certain situations may arise which will require the disposal of a live (undeployed) inflator module. Do not dispose of a live (undeployed) inflator module through normal disposal channels until the inflator module has been deployed. The following information covers the proper procedures for disposing of a live (undeployed) inflator module. Do not deploy an inflator module in the following situations: ^ After replacement of an inflator module under warranty. The inflator module may need to be returned undeployed to the manufacturer. ^ If the vehicle is the subject of a product liability report (GM-1241) related to the SIR system. When a vehicle is the subject of a product liability report, do not alter the SIR system in any manner. ^ If the vehicle is involved in a campaign affecting the inflator modules. Follow the instructions in the Campaign Service Bulletin for proper SIR handling procedures. Vehicle Scrapping Procedure Deploy inflator modules inside of the vehicle when destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations: ^ The vehicle has completed its useful life. ^ Irreparable damage occurs to the vehicle in a non-deployment type accident. ^ Irreparable damage occurs to the vehicle during a theft. ^ The vehicle is being salvaged for parts to be used on a vehicle with a different VIN as opposed to rebuilding as the same VIN. CAUTION: When you are deploying an inflator module for disposal perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11446 1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the inflatable restraint steering wheel module connector (2) located next to the steering column. 6. Cut the steering wheel module harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 8. Cut 26.1 m (15 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. Use these wires to fabricate the deployment harness. 9. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 10. Twist together 1 end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the inflator module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11447 11. Twist together 1 connector wire lead to 1 deployment wire. 12. Inspect that the previous connection is secure. 13. Bend flat the twisted connection. 14. Secure and insulate the connection using electrical tape 15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 16. Connect the deployment harness to the steering wheel module connector. 17. Route the deployment harness out of the vehicle's driver side. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11448 18. Disconnect the LF side impact module connector (1) from the vehicle wiring harness (2) located under the LF seat. 19. Cut the LF side impact module harness connector out of the vehicle leaving at least 16 cm (6 in) of wire at the connector. 20. Strip 13 mm (0.5 in) of insulation from each of the LF side impact module connector wire leads. 21. Cut 26.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. Use these wires to fabricate the deployment harness. 22. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 23. Twist together 1 end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the side impact module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11449 24. Twist together 1 connector wire lead to 1 deployment wire. 25. Inspect that the previous connection is secure. 26. Bend flat the twisted connection. 27. Secure and insulate the connection using electrical tape. 28. Twist together, bend and tape the remaining connector wire lead to the remaining deployment wire. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11450 29. Route the deployment harness out of the vehicle's driver side. 30. Disconnect the inflatable restraint IP module connector (1) located behind the glove box (3). 31. Cut the IP module harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 32. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 33. Cut 26.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used to fabricate the deployment Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11451 harness. 34. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 35. Twist together 1 end from each of the wires in order to short the wires. 36. Twist together 1 connector wire lead to 1 deployment wire. 37. Bend flat the twisted connection. 38. Secure and insulate the connection using electrical tape. 39. Twist together bend, and tape the remaining connector wire lead to the remaining deployment wire. 40. Connect the deployment harness to the IP module connector. 41. Route the deployment harness out of the vehicle's passenger side. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11452 42. Disconnect the RF side impact module connector (1) from the vehicle wiring harness (2) located under the RF seat. 43. Out the RF side impact module harness connector out of the vehicle leaving at least 16 cm (6 in) of wire at the connector. 44. Strip 13 mm (0.5 in) of insulation from each of the RF side impact module connector wire leads. 45. Gut 2 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. Use these wires to fabricate the deployment harness. 46. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 47. Twist together 1 end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the side air bag module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11453 48. Twist together 1 connector wire lead to 1 deployment wire. 49. Inspect that the previous connection is secure. 50. Bend flat the twisted connection. 51. Secure and insulate the connection using electrical tape. 52. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11454 53. Route the deployment harness out of the vehicle's passenger side. 54. Stretch the 2 driver side harnesses to full length. 55. Stretch the 2 passenger side harnesses to full length. 56. Completely cover the windshield and front door window openings with a drop cloth. 57. Place a power source, 12 V minimum/2 A minimum (i.e., a vehicle battery) near the shorted ends of the passenger side deployment harnesses. 58. Separate the 2 ends of the IP module deployment harness wires. 59. Connect the IP module deployment harness wires to the power source in order to deploy the IP module. 60. Disconnect the IP module deployment harness wires from the power source. 61. Separate the 2 ends of the RF side impact module deployment harness wires. 62. Connect the RF side impact module deployment harness wires to the power source in order to deploy the RF side impact module. 63. Disconnect the RF side impact module deployment harness wires from the power source. 64. Twist together 1 end of each wire of the IP module on the passenger side deployment harness in order to short the wires. 65. Twist together 1 end of each wire of the RF side impact module on the passenger side deployment harness in order to short the wires. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11455 66. Move the power source, 12 V minimum/2 A minimum (i.e., a vehicle battery) near the shorted ends of the driver side deployment harnesses. 67. Separate the 2 ends of the steering wheel module deployment harness wires. 68. Connect the steering wheel module deployment harness wires to the power source in order to deploy the steering wheel module. 69. Disconnect the steering wheel module deployment harness wires from the power source. 70. Separate the 2 ends of the LF side impact module deployment harness wires 71. Connect the LF side impact module deployment harness wires to the power source in order to deploy the side impact module. 72. Disconnect the LF side impact module deployment harness wires from the power source. 73. Twist together 1 end of each wire of the steering wheel module on the driver side deployment harness in order to short the wires. 74. Twist together 1 end of each wire of the LF side impact module on the driver side deployment harness in order to short the wires. 75. Remove the drop cloth from the vehicle. 76. Disconnect all harnesses from the vehicle. 77. Discard the harnesses. 78. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 79. If 1 or all of the inflator modules did not deploy, perform the following steps to remove the undeployed module(s) from the vehicle: ^ Inflatable Restraint Steering Wheel Module Replacement ^ Inflatable Restraint Instrument Panel Module Replacement ^ Inflatable Restraint Side Impact Module Replacement - Front 80. Contact the Technical Assistance Group for further assistance. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11456 Air Bag: Service and Repair Inflator Module Inflatable Restraint Steering Wheel Module Replacement REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Turn on the ignition. 3. Turn the steering wheel 90 degrees so the side of the SIR module is at the 12 O'clock position in order to gain access to the holes behind the steering wheel. 4. Insert a screwdriver into the access hole and push the leaf spring to release the notched pin that retains the inflator module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11457 5. Turn the steering wheel 180 degrees in order to gain access to the remaining hole. 6. Insert a screwdriver into the remaining access hole and push the leaf spring to release the notched pin that retains the inflator module. 7. Tilt the top of the inflator module rearward to gain access to the SIR wiring. 8. Disconnect the SIR lead wire from the clip on the inflator module. 9. Disconnect the SIR lead wire from the clip on the steering wheel. 10. Disconnect the connector position assurance (CPA) retainer from the SIR connector. 11. Disconnect the SIR connector. CAUTION: When carrying a live inflator module, make sure the bag opening is pointed away from you. This minimizes the chance of injury in the case of an accidental deployment. Never carry the inflator module by the wires. Never carry the inflator module by the connector on the underside of the module. Make sure that the bag and trim cover are facing up whenever you place a live inflator module on any surface. This is necessary to provide a Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11458 free space for the bag to expand in the unlikely event of accidental deployment. Never rest the steering column assembly on the steering wheel with the inflator module face down, and the column vertical. This may result in personal injury. 12. Remove the inflator module. 13. Fully deploy the module before disposal. If the module was replaced under warranty, fully deploy and dispose of the module after the required retention period. Refer to Inflator Module Handling and Scrapping. INSTALLATION PROCEDURE CAUTION: When carrying a live inflator module, make sure the bag opening is pointed away from you. This minimizes the chance of injury in the case of an accidental deployment. Never carry the inflator module by the wires. Never carry the inflator module by the connector on the underside of the module. Make sure that the bag and trim cover are facing up whenever you place a live inflator module on any surface. This is necessary to provide a free space for the bag to expand in the unlikely event of accidental deployment. Never rest the steering column assembly on the steering wheel with the inflator module face down, and the column vertical. This may result in personal injury. 1. Connect the SIR connector. 2. Connect the connector position assurance (CPA) retainer to the SIR connector. 3. Install the SIR lead wire to the clip on the steering wheel. IMPORTANT: Verify that the wiring is not exposed or trapped between the inflatable restraint steering wheel module and the steering wheel. 4. Install the SIR lead wire to the clip on the inflator module. 5. Press the inflator module into the steering wheel firmly enough that the module engages and latches the notched pins in the leaf springs. 6. Rotate the steering wheel back into the straight position. 7. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11459 Inflatable Restraint Instrument Panel Module Replacement CAUTION: ^ Refer to SIR Caution in Service Precautions. ^ Refer to SIR Inflator Module Handling And Storage Caution in Service Precautions. REMOVAL PROCEDURE 1. Remove upper IP trim panel. 2. Disable the SIR system. 3. Remove the connector (2) from the IP. 4. Remove the inflatable restraint IP module retaining bolts. Ensure that you keep a firm hold of the IP module. INSTALLATION PROCEDURE 1. Install the inflatable restraint IP module (1) to the mounting bracket through the front of the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fasteners to the inflatable restraint IP module. Tighten Tighten the fasteners to 10 Nm (89 lb in). 3. Enable the SIR system. 4. Install the yellow connector (2) to the IP. 5. Install the upper IP trim panel. Front Seat Side Impact Inflator Module Replacement Refer to Side Air Bag service procedures. See: Side Air Bag Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications Fastener Tightening Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations Air Bag Control Module: Component Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 11465 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 11466 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 11467 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Inflatable Restraint Sensing and Diagnostic Module (SDM) - C1 Inflatable Restraint Sensing And Diagnostic Module (SDM) - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Inflatable Restraint Sensing and Diagnostic Module (SDM) - C1 > Page 11470 Inflatable Restraint Sensing And Diagnostic Module (SDM) - C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information Air Bag Control Module: Technician Safety Information CAUTION: ^ In order to avoid deploying the air bag when troubleshooting the SIR system, use only the equipment specified in this manual and the instructions given in this manual. Failure to use the specified equipment as instructed could cause air bag deployment, personal injury to you or someone else, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. CAUTION: ^ Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to fallow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information > Page 11473 Air Bag Control Module: Vehicle Damage Warnings CAUTION: ^ In order to avoid deploying the air bag when troubleshooting the SIR system, use only the equipment specified in this manual and the instructions given in this manual. Failure to use the specified equipment as instructed could cause air bag deployment, personal injury to you or someone else, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. CAUTION: ^ Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to fallow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Page 11474 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The Sensing And Diagnostic Module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Page 11475 Air Bag Control Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT CAUTION: ^ Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to fallow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the drivers seat. 3. Remove the driver side door sill plate. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Page 11476 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. 7. Disconnect the SDM wiring harness connector (1) from the SDM (3). 8. Remove the SDM mounting fasteners. 9. Remove the SDM from the vehicle. IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10. Repair the fasteners using the following procedure: 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5 Migweld the stud at the drilled holes from above or below the floor pan (as required). 10.6. Apply body sealer GM P/N 9984248 around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Page 11477 1. Install the SDM (3) to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions 2. Install the SDM mounting fasteners. Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Connect the SDM wiring harness connector (1) to the SDM. 4. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 5. Install the connector position assurance (CPA) (1) to the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Position the carpet to cover the inflatable restraint sensing and diagnostic module (SDM). 7. Install the door sill plate. 8. Install the driver seat. Important: The AIR BAG indicator may remain ON after the SDM has been replaced. DTC B1001 may set requiring the SDM part number to be set in multiple modules. If the indicator remains ON after enabling the SIR system, perform the diagnostic system check and follow the steps thoroughly to ensure that the SDM is set properly. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check 9. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations Air Bag Deactivation Switch: Component Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations > Page 11482 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations > Page 11483 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 11484 Inflatable Restraint IP Module Disable Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Inflatable Restraint IP module Disable Switch Indicator Air Bag Deactivation Switch: Description and Operation Inflatable Restraint IP module Disable Switch Indicator The Instrument Panel (IP) module disable switch ON/OFF indicator is an LED located in a position that can been viewed by the occupants in the front seats. The location varies depending on the vehicle. When the IP module disable switch is in the disable position, the IP module disable switch indicator illuminates. When the IP module disable switch is in the enable position, the IP module disable switch indicator is not illuminated. The IP module disable switch indicator will dim to a lower intensity when the headlamp switch is turned ON. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Inflatable Restraint IP module Disable Switch Indicator > Page 11487 Air Bag Deactivation Switch: Description and Operation Inflatable Restraint IP Module Disable Switch The Instrument Panel (IP) module disable switch is a manual 2-position key switch located inside the vehicle. The IP module disable switch allows the vehicle operator the ability to enable or disable the IP module (passenger frontal air bag). The vehicle operator must disable the IP module if a rear-facing child seat is installed in the front passenger seat. The IP module disable switch interfaces with the Sensing And Diagnostic Module (SDM) to request the enabling or disabling of the IP module. The occupants are notified of the enabling or disabling of the IP module via the IP module disable switch ON/OFF indicator located in the IP module disable switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Page 11488 Air Bag Deactivation Switch: Service and Repair INFLATABLE RESTRAINT IP MODULE DISABLE SWITCH REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the instrument panel trim bezel. 3. Remove the IP module switch from the lower right opening of the switch plate panel. 4. Disconnect the IP module switch electrical connector. INSTALLATION PROCEDURE 1. Connect the IP module switch electrical connector. 2. Install the IP module switch into the lower right opening of the switch plate panel. 3. Install the instrument panel trim bezel. 4. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Inflatable Restraint Steering Wheel Module Coil Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 11492 Clockspring Assembly / Spiral Cable: Description and Operation INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL The steering wheel module coil is attached to the steering column and is located under the steering wheel. The steering wheel module cell consists of two or more current-carrying coils. The coils allow the rotation of the steering wheel while maintaining continuous electrical contact between the driver deployment loop and the steering wheel module. Two coil wires are used for the steering wheel module deployment loop. Additional coil wires are used for accessories attached to the steering wheel depending on the vehicle model. The steering wheel module coil connector is located near the base of the steering column. The connector contains a shorting bar that shorts the steering wheel module coil deployment loop circuitry to prevent unwanted deployment of the air bag when it is disconnected. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > SIR Module Coil Assembly Clockspring Assembly / Spiral Cable: Service and Repair SIR Module Coil Assembly INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL REPLACEMENT CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the steering column trim covers. 3. Remove the wire harness assembly (4) out of the wire harness strap (5). 4. Remove the 3 wire harness straps (3) from the wire harness assembly. 5. Remove the wire harness strap (2) from the upper tilt head assembly (1). 6. Remove the SIR steering wheel module coil retaining clip (1). 7. Remove the SIR steering wheel coil (2). 8. Remove the wave washer (3) from the steering column upper shaft. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > SIR Module Coil Assembly > Page 11495 1. Align the block tooth on the upper shaft to the 12 O'clock position. NOTE: Ensure all fasteners are securely seated before applying needed torque. Failure to do so may result in component damage or malfunctioning of steering column. 2. Install the wave washer (1) to the steering column upper shaft. IMPORTANT: ^ Verify that the SIR steering wheel module coil is centered. ^ The SIR steering wheel module coil becomes uncentered under the following conditions: The steering column is separated from the steering gear and allowed to rotate. - The centering spring is pushed down, letting the hub rotate while the coil is removed from the steering column. ^ If the SIR steering wheel module coil becomes uncentered, refer to the following procedures: For the standard column, refer to Inflatable Restraint Coil Centering - Off Vehicle (Column Shift And Floor Shift) in Steering Wheel and Column - Standard. - For the tilt column refer to Inflatable Restraint Coil Centering Off Vehicle (Column Shift And Floor Shift) in Steering Wheel and Column - Tilt. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > SIR Module Coil Assembly > Page 11496 3. Align the SIR steering wheel module coil (2) with the horn tower on the turn signal cancel cam (1). 4. Install the pre-centered SIR steering wheel module coil (2) to the steering column upper shaft. 5. Remove the centering tab (1) and discard. NOTE: Gently pull on the lower coil assembly wire in order to remove any wire kinks inside of the column assembly. Verify that there are NO kinks or bends in the SIR coil assembly wire. If a kink or bend is present interference may occur with the shaft lock mechanism. Turning the steering wheel may cut or damage the wire. 6. Install the SIR steering wheel module coil retaining ring. Verify that the ring (1) is firmly seated in the groove on the upper shaft (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > SIR Module Coil Assembly > Page 11497 7. Install the wire harness assembly (4) into the wire strap (5). 8. Install the wire harness strap (2) into the wire strap (1). 9. Install the wire harness straps (3) to the wire harness assembly. 10. Install the steering column trim covers. 11. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications Fastener Tightening Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Inflatable Restraint Front End Discriminating Sensors Impact Sensor: Locations Inflatable Restraint Front End Discriminating Sensors Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Inflatable Restraint Front End Discriminating Sensors > Page 11503 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Inflatable Restraint Front End Discriminating Sensors > Page 11504 Impact Sensor: Locations Inflatable Restraint Side Impact Sensors Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Inflatable Restraint Front End Discriminating Sensors > Page 11505 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Discriminating Sensor - 10/20 Sensor Inflatable Restraint Front End Discriminating Sensor - 10/20 Series Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Discriminating Sensor - 10/20 Sensor > Page 11508 Inflatable Restraint Electronic Frontal Sensor (EFS) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Discriminating Sensor - 10/20 Sensor > Page 11509 Impact Sensor: Diagrams Inflatable Restraint Side Impact Sensor (SIS) Inflatable Restraint Side Impact Sensor (SIS) - Left Inflatable Restraint Side Impact Sensor (SIS) - Right Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Technician Safety Information Impact Sensor: Technician Safety Information CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Technician Safety Information > Page 11512 Impact Sensor: Vehicle Damage Warnings CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Inflatable Restraint Front End Discriminating Sensor Impact Sensor: Description and Operation Inflatable Restraint Front End Discriminating Sensor The front end discriminating sensor is equipped on some vehicles to supplement SIR system performance. The discriminating sensor is an electro-mechanical sensor and is not part of the deployment loops, but instead provides an input to the SDM. The SDM uses the input from the discriminating sensor to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Inflatable Restraint Front End Discriminating Sensor > Page 11515 Impact Sensor: Description and Operation Inflatable Restraint Electronic Frontal Sensor (EFS) The Electronic Frontal Sensor (EFS) is equipped on some vehicles to supplement SIR system performance. The EFS is an electronic sensor (accelerometer) and is not part of the deployment loops, but instead provides an input to the SDM. The EFS can assists in determining the severity of some frontal collisions. The SDM contains a microprocessor that performs calculations using the measured accelerations. The SDM compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the frontal deployment loops deploying the frontal air bags. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Inflatable Restraint Front End Discriminating Sensor > Page 11516 Impact Sensor: Description and Operation Inflatable Restraint Side Impact Sensor The Side Impact Sensor (SIS) contains a sensing device (accelerometer) which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant air bag deployment. The SIB is not part of the deployment loop, but instead provides an input to the SDM. The SDM contains a microprocessor that performs calculations using the measured accelerations. The SDM compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the side deployment loops deploying the side air bags. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Replacement Impact Sensor: Service and Repair Front End Discriminating Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. 2. Remove the engine protection shield (if equipped). 3. Remove the connector position assurance (CPA) from the inflatable restraint front end discriminating sensor harness connector. 4. Disconnect the inflatable restraint front end discriminating sensor harness connector from the sensor. 5. Remove the mounting fasteners. 6. Remove the inflatable restraint front end discriminating sensor from the vehicle. IMPORTANT: The following procedure should be utilized in the event that the sensor mounting holes or fasteners are damaged to the extent that the sensor may no longer be properly mounted. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Replacement > Page 11519 7. Perform the following steps in order to complete the fastener repair: 7.1. Remove and discard the improperly installed fastener. 7.2. Chisel off the damaged weld nut. 7.3. Condition the front end lower tie surface where the new weld nut is to be installed. 7.4. Install the new weld nut (GM P/N 11514034) or equivalent into position. 7.5. Migweld the new weld nut to the front end lower tie surface in the correct location. 7.6. Use the new fastener (GM P/N 11515926) or equivalent. INSTALLATION PROCEDURE CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. 1. Install the inflatable restraint front end discriminating sensor to the front end lower tie surface. Make sure the arrow is pointing toward the front of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Replacement > Page 11520 2. Install the inflatable restraint front end discriminating sensor mounting fasteners. Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Connect the inflatable restraint front end discriminating sensor harness connector to the sensor. 4. Install the connector position assurance (CPA) to the inflatable restraint front end discriminating sensor harness connector. 5. Install the engine protection shield (if equipped). 6. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Replacement > Page 11521 Impact Sensor: Service and Repair Side Impact Sensor Replacement REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the front door trim panel. 3. Loosen the 2 inflatable restraint side impact sensor fasteners (2). 4. Remove the inflatable restraint side impact sensor (1) from the door (4). 5. Remove the connector position assurance (CPA) (3) and disconnect the inflatable restraint side impact sensor yellow 2-way harness connector (5). INSTALLATION PROCEDURE 1. Connect the inflatable restraint side impact sensor yellow 2-way harness connector (5) to the inflatable restraint side impact sensor (1). 2. Install the connector position assurance (CPA) (3) to the inflatable restraint side impact sensor yellow 2-way connector (5). 3. Install the inflatable restraint side impact sensor (1) to the door (4). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the fasteners (2) to the inflatable restraint side impact sensor (1). Tighten Use only hand tools in order to tighten the fasteners to 10 N.m (89 lb in). 5. Install the door trim panel. 6. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Specifications Fastener Tightening Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Inflatable Restraint Side Impact Module - Left (Seat) Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Inflatable Restraint Side Impact Module - Left (Seat) > Page 11531 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Diagrams > Left Inflatable Restraint Side Impact Module - Left Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Diagrams > Left > Page 11534 Inflatable Restraint Side Impact Module - Right Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Deployment Procedures Side Air Bag: Service and Repair Deployment Procedures General Information Inflator modules can be deployed inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation. Deployment Outside Vehicle Deploy inflator modules outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: ^ Using the SIR diagnostics, you determine that the inflator module is malfunctioning. ^ The inflator module is cosmetically damaged (scratched or ripped). ^ The inflator module pigtail (if equipped) is damaged. ^ The inflator module connector is damaged. ^ The inflator module connector terminals are damaged. Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. CAUTION: Refer to SIR Inflator Module Disposal Caution in Service Precautions. TOOLS REQUIRED ^ J 38826 SIR Deployment Harness ^ J 39401-B SIR Deployment Fixture ^ An appropriate pigtail adaptor 1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove the inflator module. CAUTION: Refer to SIR Inflator Module Handling and Storage Caution in Service Precautions. 5. Place the inflator module with the vinyl trim cover facing up and away from the surface on a work bench, floor or deployment fixture. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11537 6. Clear an area on the floor approximately 1.85 m (6 ft) in diameter for deployment of the inflator module. If possible, use a paved, outdoor location free of activity. Otherwise, use an area free of activity on the shop floor. Make sure you have sufficient ventilation. 7. Make sure no loose or flammable objects are in the area. 8. When deploying a steering wheel module, place the steering wheel module in the center of the cleared area. 9. When deploying an IP module refer to the following instructions: ^ Place the J 39401-B (2) in the center of the cleared area. ^ Fill the deployment fixture (2) with water or sand. ^ Mount the IP module (1) in the deployment fixture (2) with the vinyl/plastic trim facing up. ^ To mount, use 4 M 6 bolts (6), nuts (8), and washers (7) to properly secure the IP module (1) to the deployment fixture (2). ^ Tighten all fasteners prior to deployment. 10. When deploying a side impact module, refer to the following instructions: ^ Place the J 39401-B SIR deployment fixture (3) in the center of the cleared area. ^ Fill the deployment fixture (3) with water or sand. ^ Mount the side impact module (1) in the deployment fixture (3) with the vinyl/plastic trim facing up. ^ Adjust and secure the J 39401-B arms (4) to the deployment fixture (3). ^ To mount, use 2 M 6 x 1.0 nuts (2) with washers to secure the side impact module (1) to the deployment fixture arms (4). ^ Tighten all fasteners prior to deployment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11538 11. Inspect the J 38826 SIR deployment harness and the appropriate pigtail adapter for damage. Replace as needed. 12. Short the 2 SIR deployment harness (1) leads together using one banana plug seated into the other. 13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 14. Extend the SIR deployment harness and adapter to full length from the deployment fixture. 15. Connect the inflator module (1) to the adapter (2) on the SIR deployment harness (3). IMPORTANT: ^ The rapid expansion of gas involved with deploying an inflator module is very loud. Notify all people in the immediate area that an inflator module will be deployed. ^ When the inflator module deploys, the deployment fixture may jump vertically. This is a normal reaction of the inflator module due to the force of the rapid expansion of gas inside the inflator module. 16. Clear the area of people. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11539 17. Separate the 2 banana plugs on the SIR deployment harness. 18. Place a 12 V minimum/2 A minimum power source (i.e. vehicle battery) near the shorted end of the SIR deployment harness. 19. Connect the SIR deployment harness wires to the power source. Inflator module deployment will occur when contact is made. 20. Disconnect the SIR deployment harness from the power source 21. Seat 1 banana plug into the other in order to short the deployment harness leads. CAUTION: Refer to SIR Deployed Inflator Modules Are Hot Caution in Service Precautions. 22. If the inflator module did not deploy disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group for further assistance. Otherwise, proceed to the following steps. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11540 23. Put on a pair of shop gloves. 24. Disconnect the pigtail adapter from the inflator module as soon as possible. 25. Dispose of the deployed inflator module through normal refuse channels. 26. Wash hands with a mild soap. Vehicle Scrapping Procedure Deploy inflator modules inside of the vehicle when destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations: ^ The vehicle has completed its useful life. ^ Irreparable damage occurs to the vehicle in a non-deployment type accident. ^ Irreparable damage occurs to the vehicle during a theft. ^ The vehicle is being salvaged for parts to be used on a vehicle with a different VIN as opposed to rebuilding as the same VIN. CAUTION: When you are deploying an inflator module for disposal perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. 1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the inflatable restraint steering wheel module connector (2) located next to the steering column. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11541 6. Cut the steering wheel module harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 8. Cut 26.1 m (15 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. Use these wires to fabricate the deployment harness. 9. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 10. Twist together 1 end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the inflator module. 11. Twist together 1 connector wire lead to 1 deployment wire. 12. Inspect that the previous connection is secure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11542 13. Bend flat the twisted connection. 14. Secure and insulate the connection using electrical tape 15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 16. Connect the deployment harness to the steering wheel module connector. 17. Route the deployment harness out of the vehicle's driver side. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11543 18. Disconnect the inflatable restraint IP module connector (1) located behind the main IP support. Access the connector by opening the glove box and pressing in on the sides. This will allow the glove box to extend beyond the stops and to fully open. The IP module connector will be attached to the main IP support. 19. Cut the LF side impact module harness connector out of the vehicle leaving at least 16 cm (6 in) of wire at the connector. 20. Strip 13 mm (0.5 in) of insulation from each of the LF side impact module connector wire leads. 21. Cut 26.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. Use these wires to fabricate the deployment harness. 22. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 23. Twist together 1 end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the side impact module. 24. Twist together 1 connector wire lead to 1 deployment wire. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11544 25. Bend flat the twisted connection. 26. Secure and insulate the connection using electrical tape.7 27. Twist together, bend and tape the remaining connector wire lead to the remaining deployment wire. 28. Connect the deployment harness to the IP module connector. 29. Route the deployment harness out of the vehicle's passenger side. 30. Stretch the driver side harnesses to full length. 31. Stretch the passenger side harnesses to full length. 32. Completely cover the windshield and front door window openings with a drop cloth. 33. Place a power source, 12 V minimum/2 A minimum, i.e., a vehicle battery, near the shorted ends of the passenger side deployment hamesses. 34. Separate the 2 ends of the IP module deployment harness wires. 35. Connect the IP module deployment harness wires to the power source in order to deploy the IP module. 36. Disconnect the P module deployment harness wires from the power source. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11545 37. Twist together 1 end of each wire of the IP module on the passenger side deployment harness in order to short the wires. 38. Move the power source, 12 V minimum/2 A minimum, i.e., a vehicle battery, near the shorted ends of the driver side deployment harnesses. 39. Separate the 2 ends of the steering wheel module deployment harness wires. 40. Connect the steering wheel module deployment harness wires to the power source in order to deploy the steering wheel module. 41. Disconnect the steering wheel module deployment harness wires from the power source. 42. Twist together 1 end of each wire of the steering wheel module on the driver side deployment harness in order to short the wires. 43. Remove the drop cloth from the vehicle. 44. Disconnect all harnesses from the vehicle. 45. Discard the harnesses. 46. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 47. If 1 or all of the inflator modules did not deploy, perform the following steps to remove the undeployed module(s) from the vehicle: ^ Inflatable Restraint Steering Wheel Module Replacement ^ Inflatable Restraint Instrument Panel Module Replacement 48. Contact the Technical Assistance Group for further assistance. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11546 Side Air Bag: Service and Repair Inflator Module Handling, Shipping, and Scrapping CAUTION: Refer to SIR Inflator Module Handling and Storage Caution in Service Precautions. LIVE (UNDEPLOYED) INFLATOR MODULES Use special care when handling or storing live (undeployed) inflator modules. Inflator module deployment produces a rapid generation of gas. This may cause the inflator module, or an object in front of the inflator module, to project through the air in the event of an unlikely deployment. SCRAPPING PROCEDURES During the course of a vehicle's useful life, certain situations may arise which will require the disposal of a live (undeployed) inflator module. Do not dispose of a live (undeployed) inflator module through normal disposal channels until the inflator module has been deployed. The following information covers the proper procedures for disposing of a live (undeployed) inflator module. Do not deploy an inflator module in the following situations: ^ After replacement of an inflator module under warranty. The inflator module may need to be returned undeployed to the manufacturer. ^ If the vehicle is the subject of a product liability report (GM-1241) related to the SIR system. When a vehicle is the subject of a product liability report, do not alter the SIR system in any manner. ^ If the vehicle is involved in a campaign affecting the inflator modules. Follow the instructions in the Campaign Service Bulletin for proper SIR handling procedures. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11547 Side Air Bag: Service and Repair Front Seat Side Impact Inflator Module Replacement REMOVAL PROCEDURE CAUTION: Refer to SIR Handling Caution in cautions and Notices. 1. Disable the SIR system. 2. Remove the front seat. 3. Remove the seat back cover. 4. Remove the retaining bolts (3) that attach the inflatable restraint side impact module (1) to the seat frame. 5. Remove the inflatable restraint side impact module retainer. 6. Remove the inflatable restraint side impact module wiring harness retaining clips from the seat frame (3). IMPORTANT: Note the routing of the inflatable restraint side impact module wiring harness (2) and retaining clips within the seat frame (3). It is crucial that the wiring harness (2) be routed the exact same way as from the factory to eliminate the possibility of any cutting or chafing of the wiring harness. 7. Remove the inflatable restraint side impact module wiring harness (2) from the seat frame (3). 8. Remove the inflatable restraint side impact module (1) from the seat frame (3). INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 11548 1. Install the inflatable restraint side impact module wiring harness (2) to the seat frame (3) while guiding the wiring harness (2) through the appropriate spots on the seat frame (3). 2. Install the inflatable restraint side impact module wiring harness retaining clips to the seat frame. 3. Install the inflatable restraint side impact module (1) to the seat frame. 4. Install the inflatable restraint side impact module retainer. NOTE: Refer to Fastener Notice in Cautions and Notices. 5. Install the inflatable restraint side impact module retaining bolts (3). Tighten Use only hand tools to tighten the fasteners to 10 N.m (89 lb in). 6. Install the seat back cover. 7. Install the front seat. 8. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation AIR BAG INDICATOR The AIR BAG indicator, located in the IPC is used to notify the driver of SIR system malfunctions and to verity that the SDM is communicating with the IPC, When the ignition is turned ON, the SDM is supplied with ignition 1 voltage and the IPC flashes the AIR BAG indicator seven times. While flashing the indicator, the SDM conducts test on all SIR system components and circuits. If no malfunctions are detected the SDM will communicate with the IPC through the class 2 serial data circuit and request the IPC to turn the AIR BAG indicator OFF. The SDM provides continuous monitoring of the air bag circuits by conducting a sequence of checks. If a malfunction is detected the SDM will store a Diagnostic Trouble Code (DTC) and request the IPC to turn the AIR BAG indicator ON. The presence of a SIR system malfunction could result in non-deployment of the air bags. The AIR BAG indicator will remain ON until the malfunction has been repaired. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Description and Operation Knee Diverter: Description and Operation DRIVER AND PASSENGER KNEE BOLSTERS The knee bolsters are designed to help restrain the lower torsos of front seat occupants by absorbing energy through the front seat occupants' upper legs. In a frontal collision the front seat occupants legs may come in contact with the knee bolsters. The knee bolsters are designed to crush or deform absorbing some of the impact, which helps to reduce bodily injuries. The driver and passenger knee bolsters are located in the lower part of the instrument panel and must be inspected for damage after a collision. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Non-Luxury Knee Diverter: Service and Repair Non-Luxury KNEE BOLSTER REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP cluster trim plate bezel. 2. Remove the knee bolster screws. 3. Unsnap the top of the knee bolster from the IP assembly. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Non-Luxury > Page 11561 1. Snap the top of the knee bolster into the IP assembly. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the knee bolster screws. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the IP cluster trim plate bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Non-Luxury > Page 11562 Knee Diverter: Service and Repair Luxury KNEE BOLSTER REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP cluster trim plate bezel. 2. Move the IP extension rearwards. 3. Remove the knee bolster screws. 4. Unsnap the top of the knee bolster from the IP assembly INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Non-Luxury > Page 11563 1. Snap the top of the knee bolster into the IP assembly. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the knee bolster screws. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the IP cluster trim plate bezel. 4. Install the IP extension to the IP. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Fastener Tightening Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations Air Bag Control Module: Component Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 11570 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 11571 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 11572 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Inflatable Restraint Sensing and Diagnostic Module (SDM) - C1 Inflatable Restraint Sensing And Diagnostic Module (SDM) - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Inflatable Restraint Sensing and Diagnostic Module (SDM) - C1 > Page 11575 Inflatable Restraint Sensing And Diagnostic Module (SDM) - C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information Air Bag Control Module: Technician Safety Information CAUTION: ^ In order to avoid deploying the air bag when troubleshooting the SIR system, use only the equipment specified in this manual and the instructions given in this manual. Failure to use the specified equipment as instructed could cause air bag deployment, personal injury to you or someone else, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. CAUTION: ^ Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to fallow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information > Page 11578 Air Bag Control Module: Vehicle Damage Warnings CAUTION: ^ In order to avoid deploying the air bag when troubleshooting the SIR system, use only the equipment specified in this manual and the instructions given in this manual. Failure to use the specified equipment as instructed could cause air bag deployment, personal injury to you or someone else, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. CAUTION: ^ Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to fallow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 11579 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The Sensing And Diagnostic Module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 11580 Air Bag Control Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT CAUTION: ^ Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to fallow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the drivers seat. 3. Remove the driver side door sill plate. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 11581 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. 7. Disconnect the SDM wiring harness connector (1) from the SDM (3). 8. Remove the SDM mounting fasteners. 9. Remove the SDM from the vehicle. IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10. Repair the fasteners using the following procedure: 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5 Migweld the stud at the drilled holes from above or below the floor pan (as required). 10.6. Apply body sealer GM P/N 9984248 around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 11582 1. Install the SDM (3) to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions 2. Install the SDM mounting fasteners. Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Connect the SDM wiring harness connector (1) to the SDM. 4. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 5. Install the connector position assurance (CPA) (1) to the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Position the carpet to cover the inflatable restraint sensing and diagnostic module (SDM). 7. Install the door sill plate. 8. Install the driver seat. Important: The AIR BAG indicator may remain ON after the SDM has been replaced. DTC B1001 may set requiring the SDM part number to be set in multiple modules. If the indicator remains ON after enabling the SIR system, perform the diagnostic system check and follow the steps thoroughly to ensure that the SDM is set properly. See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check 9. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the fuse block. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Disconnect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 7. Access the IP module yellow 2-way connector (1) located behind the IP module (2) by removing the upper IP trim panel. Refer to Trim Pad Replacement - IP Upper in Instrument Panel, Gauges and Warning Indicators. 8. Remove the CPA from the IP module yellow 2-way connector (1) located behind the IP module (2). 9. Disconnect the IP module yellow 2-way connector (1) located behind the IP module (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 11588 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the IP module yellow 2-way connector (1) located behind the main IP support. 3. Install the CPA to the IP module yellow 2-way connector (1) located behind the main IP support. 4. Connect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 5. Install the CPA (1) to the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Install the AIR BAG Fuse to the fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - SIR if the AIR BAG indicator does not operate as described. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Top Teather Attachment Kits Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Top Teather Attachment Kits Bulletin No.: 99-09-40-004a Date: April 12, 2005 INFORMATION Subject: Top Tether Hardware Package for Child Restraint Seats Models: 1989-2002 Passenger Cars, Light Duty Trucks and Multi-Purpose Passenger Vehicles (Except EV1 and Prizm) Supercede: This bulletin is being revised to add the 2000-2002 model years. Please discard Corporate Bulletin Number 99-09-40-009 (Section 09 - Restraints). Important: GM of Canada and IPC Dealers are not authorized to utilize this service bulletin. Beginning in August, 1997 General Motors began providing Child Restraint Seat Top Tether Hardware Packages to customers in the United States who requested them. The Top Tether Hardware Package contains the necessary hardware for anchoring a forward facing child restraint seat top tether. One Child Restraint Seat Top Tether Hardware Package will be provided per vehicle to the retail customer at no charge for installation. Charges for installation of additional Top Tether Hardware Packages per vehicle are the responsibility of the customer. Most forward facing child restraint seats (CRS) sold in the United States prior to calendar year 1999 were not sold with top tether straps, but have provisions for them. Top tethers, which are required in Canada, can help to better secure the seat in the vehicle. When a forward facing CRS including a top tether is used, specially designed components must be used to secure the child seat top tether. These components are included in the Hardware Package from GMSPO. Top tethers are not normally required or used with rearward facing infant restraint seats. Rearward facing infant restraint seats should never be secured in the front seat of an air bag equipped vehicle unless the vehicle is equipped with an air bag de-activation (shut-off) switch and the switch has been used to turn the air bag off. Should a retail customer request installation of a Tether Hardware Package at the time of sale or delivery, it is to be installed at no charge to the owner. The labor to install a Tether Hardware Package prior to delivery of a new vehicle to the customer is considered to be part of the delivery "get ready process", and as such, is not claimable. Claiming for the cost and applicable handling allowance of the proper Tether Hardware Package used in the installation is allowed. If the customer requests installation of a Tether Hardware Package some time after delivery, the package is to be provided free of charge. Hardware Packages include installation instructions which are easily followed and can be installed by most customers. However, should the customer request the dealership's assistance to install the Tether Hardware Package, it is to be installed at no charge to the customer and the labor may be claimed. All claims submitted for installation labor of an approved Tether Hardware Package must be supported by a signed customer work order. Additional Hardware Packages and installation charges are the responsibility of the customer. In addition, passenger vehicle deliveries, including vans and sport utilities for daily rental usage, may have one tether hardware package supplied. Additional packages are the owner's responsibility. Dealers may claim appropriate parts under these circumstances. Sufficient quantities of parts should be ordered in advance of the arrival of vehicles to avoid delays. Important: When installing a Child Restraint Seat Top Tether Hardware Package, follow the installation instructions included in the package. Additional information about specific mounting locations and installations may be available in the Seat Belt Section (Sections 9, 10-10, 10-11 or 10A) I of the appropriate Service Manual, or the Restraints section of SI. Any questions regarding this policy should be directed to your Area Manager, Parts or Service. Parts Information For Top Tether Hardware Package part numbers and usage, see Group 14.870 (passenger cars & U-van), or Group 16.710 (Light Duty Truck) of the appropriate GMSPO Parts Catalog. In addition, they can also be found in Accessories Group 21.042. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Top Teather Attachment Kits > Page 11594 Warranty Information The dealership will be reimbursed for the parts and labor, if applicable, through the submission of a regular warranty claim. All claims submitted must be supported by a signed customer work order. Purchase and installation of additional Hardware Packages is the responsibility of the customer. For Top Tether Hardware Packages installed in the United States, submit as a normal warranty claim using the labor operations and time allowances shown. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Seat Tether Outer Hardware Kit Child Seat Tether Attachment: Service and Repair Child Seat Tether Outer Hardware Kit INSTALLATION PROCEDURE CAUTION: Refer to Belt Replacement Caution in Service Precautions. 1. Remove the seat. 2. Remove the trim panel off the sheet metal below the rear window. 3. Remove the carpet off the rear panel. 4. Locate the position where the hole will be drilled from inside the cab. Locate the hole either 109 mm (4.3 in) or 545 mm (21.4 in) outboard from the center line of the back panel and 42 mm (1.65 in) below the horizontal sheet metal panel. 5. Drill a 9 mm (1/8 in) hole through the sheet metal from inside the cab. Use a drill stop to prevent damage to the pickup box. 6. Place the washer on the bolts. 7. Apply a bead sealer around the hole in the washer. 8. Using a clamping tool, feed the bolts through the hole from the outside of the cab. NOTE: Refer to Fastener Notice in Service Precautions. 9. Thread the nut on the bolts. Hold the bolt head with an extended length wrench. Tighten Tighten the nut to 30 N.m (22 lb ft). 10. In the extended cab, if the length of the bolts interferes with the rear seat in the folded position, saw off the end of the bolts. Leave at least 2 threads visible from the end of the nut. 11. If the child seat anchorage is removed, properly reseal the 9 mm (1/8 in) diameter hole. 12. Install the seat. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Seat Tether Outer Hardware Kit > Page 11597 Child Seat Tether Attachment: Service and Repair Suburban With 3RD Seat (AS3) SUBURBAN WITH 3RD SEAT (AS3) 1. If you put the child seat in the 2nd seat center folding position or in the 2nd seat left folding position, use the 3rd seat center occupant lap belt latch plate if the seat is unoccupied. 2. If you put the child seat in the 2nd seat right folding position, use GM P/N 15971501 in order to latch the tether to the 3rd seat buckle directly behind this child seat position if the seat is unoccupied. 3. If you put the child seat in the 3rd seat center, use GM P/N 15989781 to the rearmost set of the cargo tie downs. Hook the top tether to the plate at the center of the tether. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Seat Tether Outer Hardware Kit > Page 11598 4. If you put the child seal in the 3rd seat left, use the left rear cargo tie down. If you put the child seat in the 3rd seat right, use the right rear cargo tie down. 5. If all seats are occupied, then place the child seat in a rear seat position that will allow the use of the cargo tie downs. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID See: Application and ID Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Seat Tether Outer Hardware Kit > Page 11599 Child Seat Tether Attachment: Service and Repair Utility-2 Door and 4 Door 1. If you put the child seat in the 2nd seat left folding position, use the left front cargo tie down (Suburban without 3rd folding seat). 2. If you put the child seat in the 2nd seat right folding position, use the right front cargo tie down (Suburban without 3rd folding seat). 3. If you put the child seat in the 3rd seat left (Suburban with 3rd seat) or in the 2nd seat loft (Utility), use the left rear cargo tie down. 4. If you put the child seat in the 3rd seat right (Suburban with 3rd seat) or in the 2nd seat right (Utility), use the right rear cargo tie down. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID See: Application and ID Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Seat Tether Outer Hardware Kit > Page 11600 Child Seat Tether Attachment: Service and Repair Utility-4-Door With 2ND Folding Seat (AM7) SUBURBAN WITH 2ND FOLDING SEAT (AT5), UTILITY-4-DOOR WITH 2ND FOLDING SEAT (AM7) 1. Position the child seat in the front seat right. Use GM P/N 15971501 in order to latch the tether to the buckle on the 2nd 40 percent seat if the seat is unoccupied. 2. Position the child seat in the front seat center. Use 2nd seat center occupant lap belt latch plate if seat is unoccupied. 3. Position the child seat in the 2nd seat center. Use GM P/N 15989781 to the rear most set of cargo tie downs. Hook the top tether to the plate at the center of the tether. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Seat Tether Outer Hardware Kit > Page 11601 4. Position the child seat in the 2nd seat left. Use the left rear cargo tie down. 5. Position the child seat in the 2nd seat right. Use the right rear cargo tie down. 6. If all seats are occupied, then place the child seat in a rear seat position that will allow the use of the cargo tie downs. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID See: Application and ID Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Front Seat Belt - Retractor and Buckle Replacement Seat Belt: Technical Service Bulletins Front Seat Belt - Retractor and Buckle Replacement File In Section: 09 - Restraints Bulletin No.: 01-09-40-001 Date: June, 2001 INFORMATION Subject: Replacement Front Seat Belt Retractor and Buckle Usage Models: 1999-2002 Chevrolet and GMC C/K Pickup Models (Silverado, Avalanche, Sierra) 2000-2002 Chevrolet and GMC C/K Utility Models (Tahoe, Yukon, Denali, Suburban and Yukon XL) 2002 Cadillac Escalade The above listed vehicles were produced with seat belt retractors and buckles supplied by different manufacturers. Because of design differences between the different manufacturers, if replacement of a front seat belt retractor or buckle is required on these vehicles you must install a replacement part made by the same manufacturer. In order to determine the manufacturer of a seat belt retractor being replaced, inspect the label or tag located on the belt webbing material. The name of the manufacturer will be printed on the tag. If a replacement seat belt buckle is required, again refer to the label or tag on the retractor seat belt webbing material. The name of the manufacturer on that retractor is also the name of the manufacturer on that buckle. Caution: To Avoid personal injury to the occupants of the vehicle, observe the following precautions: ^ More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. ^ To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. To obtain the correct replacement part number for the seat belt retractor or buckle. take the name of the manufacturer of the part being replaced and refer to the appropriate group in the Parts Catalog. Also. replacement seat belt retractor part numbers can ne obtained by calling PARTECH on 1-800-433-6961 (U.S. dealers). If contacting PARTECH, obtain the "casting number" from the same label or tag described above prior to calling. Canadian dealers should fax requests to GMSPO Canada NPN desk at 1-877-441-4985 (Attention to: Light Duty Truck NPN). Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 11606 Fastener Tightening Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 11607 Seat Belt: Service Precautions ^ Do not bleach or dye the seat belt webbing. Use only the following items in order to clean the seat belt webbing: A mild soap and water solution - A soft brush or cloth ^ Keep sharp edges and damaging objects away from the seat belts. Do not bend or damage any part of the seat belt buckle or the latch plate. Replace any seat belts that are cut or damaged in any manner. ^ Use only the correct seat belt anchor nuts/bolts. Tighten the correct seat belt anchor nut/bolt/screw to the correct torque value. Refer to Fastener Tightening Specifications. ^ Some seat belts and retractors require service as a set with service replacement components only. Do not repair individual components that must require service as a set. ^ Verify that the replacement part number is correct for the vehicle at that seating position. Do not substitute a seat belt from a different seating position. ^ Replace any seat belts that have a visible caution label instructing replacement. ^ Some seat belts have an energy management loop. An energy management loop is an overlap of the seat belt webbing that is stitched together. If any separated stitching exists, replace the seat belt. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Description and Operation > Front Seat Belt System Operation Seat Belt: Description and Operation Front Seat Belt System Operation CAUTION: To help avoid personal injury from unrepaired crash damage to a restraint system: ^ Replace each seat belt system worn during a crash unless the crash was minor. ^ Perform the seat belt check tar each seat belt system. Replace the seat belt system if there is any doubt about the condition of system components. 1. The front seat belt system includes a driver and/or passenger seat belt retractor and buckle. 2. The LF seat belt system, includes a seat belt switch in the LF seat buckle which controls a fasten safety belts indicator and a tone alarm. When the LF seat belt is buckled, the LF door closed, and the ignition switch is in the ON position, the following events occur: ^ The tone alarm will not operate. ^ The fasten safety belts indicator will not operate. 3. When the LF seat belt is not buckled, the LF door closed, and the ignition switch is in the RUN position, the following events will occur: ^ The tone alarm will operate for 4 to 8 seconds and then turn OFF. ^ The fasten safety belts indicator will operate for 20 seconds, until the LF seat bell is buckled. ^ Then the fasten safety belts indicator will flash for an additional 55 seconds before turning OFF. To diagnose a failure of the fasten safety belts indicator refer to Symptoms Seat Belts or the tone alarm, refer to Audible Warnings in Instrument Panel, Gauges and Warning Indicators. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Description and Operation > Front Seat Belt System Operation > Page 11610 Seat Belt: Description and Operation Seat Belt System Circuit Description The fasten safety belts indicator will illuminate when the following conditions occur simultaneously: ^ The ignition switch is in one of the following positions: RUN - BULB TEST - START ^ The LF safety belt is not fastened. The audio fasten safety belt warning alarm, located within the Body Control Module (BCM), also incorporates an indicator within the Instrument Panel Cluster (IPC). The fasten safety belt indicator works in conjunction with the fasten safety belt warning alarm. When the BCM receives a signal that the LF safety belt is unfastened, the BCM sends a signal to the IPC to command ON the fasten safety belt indicator. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Description and Operation > Page 11611 Seat Belt: Service and Repair SEAT BELT REPLACEMENT - CENTER FRONT REMOVAL PROCEDURE 1. Remove the center front seat belt latch bolt. Remove the seat belt latch assembly from the vehicle. 2. Remove the center front seat belt buckle bolt. 3. Remove the buckle assembly from the seat. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Description and Operation > Page 11612 1. Install the seat belt buckle assembly to the center front Seat. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the seat belt buckle bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). 3. Install the seat belt latch assembly to the center front seat. 4. Install the seat belt latch bolt. Tighten Tighten the bolt to 53 N.m (30 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 11621 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 11627 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 01-09-40-001 > Jun > 01 > Front Seat Belt - Retractor and Buckle Replacement Seat Belt Buckle: All Technical Service Bulletins Front Seat Belt - Retractor and Buckle Replacement File In Section: 09 - Restraints Bulletin No.: 01-09-40-001 Date: June, 2001 INFORMATION Subject: Replacement Front Seat Belt Retractor and Buckle Usage Models: 1999-2002 Chevrolet and GMC C/K Pickup Models (Silverado, Avalanche, Sierra) 2000-2002 Chevrolet and GMC C/K Utility Models (Tahoe, Yukon, Denali, Suburban and Yukon XL) 2002 Cadillac Escalade The above listed vehicles were produced with seat belt retractors and buckles supplied by different manufacturers. Because of design differences between the different manufacturers, if replacement of a front seat belt retractor or buckle is required on these vehicles you must install a replacement part made by the same manufacturer. In order to determine the manufacturer of a seat belt retractor being replaced, inspect the label or tag located on the belt webbing material. The name of the manufacturer will be printed on the tag. If a replacement seat belt buckle is required, again refer to the label or tag on the retractor seat belt webbing material. The name of the manufacturer on that retractor is also the name of the manufacturer on that buckle. Caution: To Avoid personal injury to the occupants of the vehicle, observe the following precautions: ^ More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. ^ To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. To obtain the correct replacement part number for the seat belt retractor or buckle. take the name of the manufacturer of the part being replaced and refer to the appropriate group in the Parts Catalog. Also. replacement seat belt retractor part numbers can ne obtained by calling PARTECH on 1-800-433-6961 (U.S. dealers). If contacting PARTECH, obtain the "casting number" from the same label or tag described above prior to calling. Canadian dealers should fax requests to GMSPO Canada NPN desk at 1-877-441-4985 (Attention to: Light Duty Truck NPN). Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 01-09-40-001 > Jun > 01 > Front Seat Belt Retractor and Buckle Replacement Seat Belt Buckle: All Technical Service Bulletins Front Seat Belt - Retractor and Buckle Replacement File In Section: 09 - Restraints Bulletin No.: 01-09-40-001 Date: June, 2001 INFORMATION Subject: Replacement Front Seat Belt Retractor and Buckle Usage Models: 1999-2002 Chevrolet and GMC C/K Pickup Models (Silverado, Avalanche, Sierra) 2000-2002 Chevrolet and GMC C/K Utility Models (Tahoe, Yukon, Denali, Suburban and Yukon XL) 2002 Cadillac Escalade The above listed vehicles were produced with seat belt retractors and buckles supplied by different manufacturers. Because of design differences between the different manufacturers, if replacement of a front seat belt retractor or buckle is required on these vehicles you must install a replacement part made by the same manufacturer. In order to determine the manufacturer of a seat belt retractor being replaced, inspect the label or tag located on the belt webbing material. The name of the manufacturer will be printed on the tag. If a replacement seat belt buckle is required, again refer to the label or tag on the retractor seat belt webbing material. The name of the manufacturer on that retractor is also the name of the manufacturer on that buckle. Caution: To Avoid personal injury to the occupants of the vehicle, observe the following precautions: ^ More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. ^ To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. To obtain the correct replacement part number for the seat belt retractor or buckle. take the name of the manufacturer of the part being replaced and refer to the appropriate group in the Parts Catalog. Also. replacement seat belt retractor part numbers can ne obtained by calling PARTECH on 1-800-433-6961 (U.S. dealers). If contacting PARTECH, obtain the "casting number" from the same label or tag described above prior to calling. Canadian dealers should fax requests to GMSPO Canada NPN desk at 1-877-441-4985 (Attention to: Light Duty Truck NPN). Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Page 11637 Fastener Tightening Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Page 11638 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Page 11639 Seat Belt Buckle: Service Precautions CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: ^ More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. ^ To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle Replacement - Front Seat Belt Buckle: Service and Repair Seat Belt Buckle Replacement - Front REMOVAL PROCEDURE 1. Remove the front seat belt buckle nut (1). Disconnect the electrical connection (2). The right seat buckle is shown, the left is similar. 2. Remove the seat belt buckle from the vehicle. INSTALLATION PROCEDURE 1. Install the seat belt buckle in the vehicle. 2. Connect the electrical connection (2). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the front seat belt buckle nut (1). Tighten Tighten the nut to 53 N.m (39 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle Replacement - Front > Page 11642 Seat Belt Buckle: Service and Repair Seat Belt Buckle and Latch Replacement - Rear REMOVAL PROCEDURE 1. Pull the seat belt buckles through the rear seat cushion. Fold the rear seat up. 2. Remove the rear seat belt buckle nuts. 3. Remove the buckle assembly. INSTALLATION PROCEDURE 1. Position the buckle assembly to the floor panel stud. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear seat belt buckle nuts. Tighten Tighten the nuts to 53 N.m (39 lb ft). 3. Fold the rear seat down. 4. Pull the seat belt buckles through the seat cushion. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Locations View In the seat belt buckle Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 11646 Seat Belt Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Front Seat Belt - Retractor and Buckle Replacement Seat Belt Retractor: Technical Service Bulletins Front Seat Belt - Retractor and Buckle Replacement File In Section: 09 - Restraints Bulletin No.: 01-09-40-001 Date: June, 2001 INFORMATION Subject: Replacement Front Seat Belt Retractor and Buckle Usage Models: 1999-2002 Chevrolet and GMC C/K Pickup Models (Silverado, Avalanche, Sierra) 2000-2002 Chevrolet and GMC C/K Utility Models (Tahoe, Yukon, Denali, Suburban and Yukon XL) 2002 Cadillac Escalade The above listed vehicles were produced with seat belt retractors and buckles supplied by different manufacturers. Because of design differences between the different manufacturers, if replacement of a front seat belt retractor or buckle is required on these vehicles you must install a replacement part made by the same manufacturer. In order to determine the manufacturer of a seat belt retractor being replaced, inspect the label or tag located on the belt webbing material. The name of the manufacturer will be printed on the tag. If a replacement seat belt buckle is required, again refer to the label or tag on the retractor seat belt webbing material. The name of the manufacturer on that retractor is also the name of the manufacturer on that buckle. Caution: To Avoid personal injury to the occupants of the vehicle, observe the following precautions: ^ More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. ^ To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. To obtain the correct replacement part number for the seat belt retractor or buckle. take the name of the manufacturer of the part being replaced and refer to the appropriate group in the Parts Catalog. Also. replacement seat belt retractor part numbers can ne obtained by calling PARTECH on 1-800-433-6961 (U.S. dealers). If contacting PARTECH, obtain the "casting number" from the same label or tag described above prior to calling. Canadian dealers should fax requests to GMSPO Canada NPN desk at 1-877-441-4985 (Attention to: Light Duty Truck NPN). Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 11655 Fastener Tightening Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 11656 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 11657 Seat Belt Retractor: Service Precautions CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: ^ More than one supplier's seat belts are used, therefore, Install ONLY the seat belt components specified In the GM parts catalog. ^ To verify that the correct seat belt components were Installed1 Insert the seat belt latch In the seat belt buckle. The latch must be fully seated and be retained In the buckle until purposely released . Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front Seat Belt Retractor: Service and Repair Left Front REMOVAL PROCEDURE 1. Move the front seat to the full forward position. IMPORTANT: Do not remove the seat back cover from the head restraint retainers. 2. Remove the seat back cover and pad. 3. Separate the seat foam from the cardboard to gain access to the retainer on the seat belt side. 4. Remove the seat belt side cardboard retainers. 5. Move the cardboard outwards to gain access to the lower seat belt retractor bolt. 6. Remove the retractor bolt. 7. Remove the retractor tower retaining screw. 8. Remove the retractor tower cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 11660 9. Remove the upper anchor bolt. 10. Remove the retractor from the seat. INSTALLATION PROCEDURE 1. Position the seat belt retractor onto the seat. Line up the tab on the retractor to the tab on the seat frame. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the upper anchor bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 11661 3. Install the retractor tower cover. 4. Install the retractor tower cover retaining screw. Tighten Tighten the screw to 2 N.m (18 lb in). 5. Install the retractor. 6. Install the retractor bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). 7. Install the rear cardboard panel retainers. 8. Install the seat back cover and pad. 9. Move the seat to its original position. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 11662 Seat Belt Retractor: Service and Repair Right Front REMOVAL PROCEDURE 1. Move the front seat to the full forward position. IMPORTANT: Do not remove the seat back cover from the head restraint retainers. 2. Remove the seat back cover and pad. 3. Separate the seat foam from the cardboard to gain access to the retainer on the seat belt side. 4. Remove the seat belt side cardboard retainers. 5. Move the cardboard outwards to gain access to the lower seat belt retractor bolt. 6. Remove the retractor bolt. 7. Remove the retractor tower retaining screw. 8. Remove the retractor tower cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 11663 9. Remove the upper anchor bolt. 10. Remove the retractor from the seat. INSTALLATION PROCEDURE 1. Position the seat belt retractor onto the seat. Line up the tab on the retractor to the tab on the seal frame. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the upper anchor bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 11664 3. Install the retractor tower cover. 4. Install the retractor tower cover retaining screw. Tighten Tighten the screw to 2 N.m (18 lb in). 5. Install the retractor. 6. Install the retractor bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). 7. Install the rear cardboard panel retainers. 8. Install the seat back cover and pad. 9. Move the seat to its original position. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations Air Bag Deactivation Switch: Component Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations > Page 11670 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations > Page 11671 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 11672 Inflatable Restraint IP Module Disable Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Inflatable Restraint IP module Disable Switch Indicator Air Bag Deactivation Switch: Description and Operation Inflatable Restraint IP module Disable Switch Indicator The Instrument Panel (IP) module disable switch ON/OFF indicator is an LED located in a position that can been viewed by the occupants in the front seats. The location varies depending on the vehicle. When the IP module disable switch is in the disable position, the IP module disable switch indicator illuminates. When the IP module disable switch is in the enable position, the IP module disable switch indicator is not illuminated. The IP module disable switch indicator will dim to a lower intensity when the headlamp switch is turned ON. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Inflatable Restraint IP module Disable Switch Indicator > Page 11675 Air Bag Deactivation Switch: Description and Operation Inflatable Restraint IP Module Disable Switch The Instrument Panel (IP) module disable switch is a manual 2-position key switch located inside the vehicle. The IP module disable switch allows the vehicle operator the ability to enable or disable the IP module (passenger frontal air bag). The vehicle operator must disable the IP module if a rear-facing child seat is installed in the front passenger seat. The IP module disable switch interfaces with the Sensing And Diagnostic Module (SDM) to request the enabling or disabling of the IP module. The occupants are notified of the enabling or disabling of the IP module via the IP module disable switch ON/OFF indicator located in the IP module disable switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Page 11676 Air Bag Deactivation Switch: Service and Repair INFLATABLE RESTRAINT IP MODULE DISABLE SWITCH REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the instrument panel trim bezel. 3. Remove the IP module switch from the lower right opening of the switch plate panel. 4. Disconnect the IP module switch electrical connector. INSTALLATION PROCEDURE 1. Connect the IP module switch electrical connector. 2. Install the IP module switch into the lower right opening of the switch plate panel. 3. Install the instrument panel trim bezel. 4. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Fastener Tightening Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Inflatable Restraint Front End Discriminating Sensors Impact Sensor: Locations Inflatable Restraint Front End Discriminating Sensors Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Inflatable Restraint Front End Discriminating Sensors > Page 11682 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Inflatable Restraint Front End Discriminating Sensors > Page 11683 Impact Sensor: Locations Inflatable Restraint Side Impact Sensors Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Inflatable Restraint Front End Discriminating Sensors > Page 11684 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Discriminating Sensor - 10/20 Sensor Inflatable Restraint Front End Discriminating Sensor - 10/20 Series Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Discriminating Sensor - 10/20 Sensor > Page 11687 Inflatable Restraint Electronic Frontal Sensor (EFS) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Inflatable Restraint Front End Discriminating Sensor - 10/20 Sensor > Page 11688 Impact Sensor: Diagrams Inflatable Restraint Side Impact Sensor (SIS) Inflatable Restraint Side Impact Sensor (SIS) - Left Inflatable Restraint Side Impact Sensor (SIS) - Right Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Technician Safety Information Impact Sensor: Technician Safety Information CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Technician Safety Information > Page 11691 Impact Sensor: Vehicle Damage Warnings CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Inflatable Restraint Front End Discriminating Sensor Impact Sensor: Description and Operation Inflatable Restraint Front End Discriminating Sensor The front end discriminating sensor is equipped on some vehicles to supplement SIR system performance. The discriminating sensor is an electro-mechanical sensor and is not part of the deployment loops, but instead provides an input to the SDM. The SDM uses the input from the discriminating sensor to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Inflatable Restraint Front End Discriminating Sensor > Page 11694 Impact Sensor: Description and Operation Inflatable Restraint Electronic Frontal Sensor (EFS) The Electronic Frontal Sensor (EFS) is equipped on some vehicles to supplement SIR system performance. The EFS is an electronic sensor (accelerometer) and is not part of the deployment loops, but instead provides an input to the SDM. The EFS can assists in determining the severity of some frontal collisions. The SDM contains a microprocessor that performs calculations using the measured accelerations. The SDM compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the frontal deployment loops deploying the frontal air bags. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Inflatable Restraint Front End Discriminating Sensor > Page 11695 Impact Sensor: Description and Operation Inflatable Restraint Side Impact Sensor The Side Impact Sensor (SIS) contains a sensing device (accelerometer) which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant air bag deployment. The SIB is not part of the deployment loop, but instead provides an input to the SDM. The SDM contains a microprocessor that performs calculations using the measured accelerations. The SDM compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the side deployment loops deploying the side air bags. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Replacement Impact Sensor: Service and Repair Front End Discriminating Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. 2. Remove the engine protection shield (if equipped). 3. Remove the connector position assurance (CPA) from the inflatable restraint front end discriminating sensor harness connector. 4. Disconnect the inflatable restraint front end discriminating sensor harness connector from the sensor. 5. Remove the mounting fasteners. 6. Remove the inflatable restraint front end discriminating sensor from the vehicle. IMPORTANT: The following procedure should be utilized in the event that the sensor mounting holes or fasteners are damaged to the extent that the sensor may no longer be properly mounted. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Replacement > Page 11698 7. Perform the following steps in order to complete the fastener repair: 7.1. Remove and discard the improperly installed fastener. 7.2. Chisel off the damaged weld nut. 7.3. Condition the front end lower tie surface where the new weld nut is to be installed. 7.4. Install the new weld nut (GM P/N 11514034) or equivalent into position. 7.5. Migweld the new weld nut to the front end lower tie surface in the correct location. 7.6. Use the new fastener (GM P/N 11515926) or equivalent. INSTALLATION PROCEDURE CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. 1. Install the inflatable restraint front end discriminating sensor to the front end lower tie surface. Make sure the arrow is pointing toward the front of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Replacement > Page 11699 2. Install the inflatable restraint front end discriminating sensor mounting fasteners. Tighten Tighten fasteners to 10 N.m (89 lb in). 3. Connect the inflatable restraint front end discriminating sensor harness connector to the sensor. 4. Install the connector position assurance (CPA) to the inflatable restraint front end discriminating sensor harness connector. 5. Install the engine protection shield (if equipped). 6. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Replacement > Page 11700 Impact Sensor: Service and Repair Side Impact Sensor Replacement REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the front door trim panel. 3. Loosen the 2 inflatable restraint side impact sensor fasteners (2). 4. Remove the inflatable restraint side impact sensor (1) from the door (4). 5. Remove the connector position assurance (CPA) (3) and disconnect the inflatable restraint side impact sensor yellow 2-way harness connector (5). INSTALLATION PROCEDURE 1. Connect the inflatable restraint side impact sensor yellow 2-way harness connector (5) to the inflatable restraint side impact sensor (1). 2. Install the connector position assurance (CPA) (3) to the inflatable restraint side impact sensor yellow 2-way connector (5). 3. Install the inflatable restraint side impact sensor (1) to the door (4). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the fasteners (2) to the inflatable restraint side impact sensor (1). Tighten Use only hand tools in order to tighten the fasteners to 10 N.m (89 lb in). 5. Install the door trim panel. 6. Enable the SIR system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Locations View In the seat belt buckle Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 11704 Seat Belt Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11714 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11715 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11716 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11717 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11718 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11719 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11720 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11721 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11722 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11723 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11724 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11725 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11726 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11727 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11728 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11729 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11730 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11731 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11732 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11733 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11734 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11735 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11736 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11737 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11738 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11739 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11740 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11741 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11742 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11743 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 11744 Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) POWER MODE RAP is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its shut-off limit. The body control module monitors the ignition switch position, battery condition and passenger compartment door status to determine whether RAP should be initiated. If the ignition switch transitions from RUN/ON to OFF, the battery level is within the acceptable range and the passenger compartment doors are closed, the body control module closes the RAP relay. This provides power for the following: ^ Sunroof ^ Power windows ^ Power door locks ^ Radio ^ Rear radio ^ OnStar The BCM turns OFF the RAP function and opens the RAP relay when one of the following conditions are met: ^ The BCM senses the opening of any door or the liftgate. ^ The BCM detects a decrease in battery capacity below a prescribed limit. ^ The BCM receives a message from its internal timer indicating the end of the RAP period after 20 minutes. ^ The transition from OFF to RUN/ON or ACC of the ignition switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Accessory Delay Module Begin the system diagnosis with the Diagnostic System Check Accessory Delay Module. The Diagnostic System Check will provide the following information: ^ The identification of the control module which commands the system ^ The ability of the control module to communicate through the serial data circuit ^ The identification of any stored DTCs and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Accessory Delay Module DIAGNOSTIC SYSTEM CHECK - ACCESSORY DELAY MODULE TEST DESCRIPTION Steps 1-5 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. This step is checking for DTCs in the BCM. 5. This step is checking for RAP specific DTCs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11747 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms - Accessory Delay Module IMPORTANT PRELIMINARY CHECKS BEFORE STARTING 1. Perform the Diagnostic System Check - Retained Accessory Power before using the Symptom Tables in order to verify that all of the following are true: ^ There are no DTCs set. ^ The control module(s) can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check - Accessory Delay Module 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory Power (RAP) Description and Operation. VISUAL/PHYSICAL INSPECTION ^ Inspect for aftermarket devices which could affect the operation of the Retained Accessory Power system. Refer to Checking Aftermarket Accessories in Diagnostic Aids. ^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in Diagnostic Aids. SYMPTOM LIST Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: ^ Retained Accessory Power (RAP) On After Timeout ^ Retained Accessory Power (RAP) Inoperative Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11748 Steps 1-10 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11749 Steps 1-9 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11750 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions MODULE INFORMATION 1 Julian Date of Build: The scan tool displays the date upon which the Body Control Module (BCM) was manufactured. Manufacture Enable Counter (MEC): The scan tool displays the actual value for the MEC in the BCM. This information is for the assembly plant only. Module Part Number: The scan tool displays the part number assigned to the BCM that is currently in the vehicle. Software Design Suffix: The scan tool displays the version of the software part number in the BCM. Software Part Number: The scan tool displays the software identification number (ID) in the BCM. MODULE INFORMATION 2 Retained Accessory Power (RAP) Calibration Number: The scan tool displays the RAP calibration part number in the BCM. Retained Accessory Power (RAP) Suffix: The scan tool displays the RAP identification number in the BCM. DATA Battery Voltage: The scan tool displays the battery system voltage. Inadvertent Power Timer: The scan tool displays the seconds left before the BCM turns the inadvertent power relay OFF. The BCM uses this feature to protect the battery against inadvertent battery rundown caused by components that are part of the courtesy lamp circuit. The inadvertent power relay is supplied power by the BCM for 2400 seconds / 40 minutes after the ignition is turned OFF. RAP Timer: The scan tool displays the seconds left before the BCM turns the RAP relay OFF. The BCM uses this feature to allow the operation of the radio and the power windows for up to 1198 seconds / 20 minutes after the ignition is turned OFF. After the time has elapsed or the door is opened the BCM will open the ground circuit for the RAP relay. INPUT 1 Door Handle Switch: The scan tool displays the position of the door handle. The scan tool displays ACTIVE when a door handle is raised and INACTIVE with all doors closed and the door handles at rest. Drivers Door Jamb Switch: The scan tool displays the position of the drivers door. The scan tool displays ACTIVE when the drivers door is open. Ignition 1: The scan tool displays the position of the ignition switch. The scan tool displays ACTIVE when the ignition switch is in the RUN or CRANK position. Ignition 3: The scan tool displays the position of the ignition switch. The scan tool displays ACTIVE when the ignition switch is in the RUN position only. Ignition Power Mode: The scan tool displays the position of the ignition switch. The scan tool displays OFF, RUN, CRANK and UNKNOWN. The UNKNOWN display is when the BCM can not determine the position of the ignition switch. Key In Ignition: The scan tool displays the position of the ignition key in the ignition switch cylinder. The scan tool displays YES when the ignition key is completely inserted into the ignition switch cylinder. The BCM uses this data in controlling the operation of the reminder chime feature. RAP Relay Feedback: The scan tool displays the state of the RAP relay. The scan tool displays ON when the BCM activates the RAP relay. OUTPUTS RAP Relay: The scan tool displays the commanded state of the RAP relay. The scan tool displays ON when the BCM allows the RAP relay to go to ground. The BCM will allow operation of the radio and the power windows with the ignition OFF and the doors closed for up to 1198 seconds, approximately 20 minutes. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11751 Scan Tool Data List Scan Tool Output Controls Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Service and Repair Antenna Control Module: Service and Repair RADIO ANTENNA MODULE REPLACEMENT REMOVAL PROCEDURE The Radio control module and the Radio Antenna module cannot be replaced individually. 1. Lower the rear of the headliner. Refer to Headliner Replacement in Interior Trim. 2. Disconnect the wire harness (2) attached to the rear quarter glass panel. 3. Remove the module (3) retaining bolt. 4. Disconnect the antenna cable from the module. 5. Remove the antenna module from the roof. 6. Remove the radio control module. INSTALLATION PROCEDURE 1. Install the radio control module. 2. Install the antenna module to the roof. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the module retaining bolt. Tighten Tighten the retaining bolt to 9 N.m (80 lb in). 4. Connect the antenna cable to the module (3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Service and Repair > Page 11756 5. Connect the wire harness (2) to the rear quarter glass panel. 6. Install the rear of the headliner. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: Customer Interest Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 11770 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: All Technical Service Bulletins Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 11780 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > Page 11781 Antenna, Navigation: Service and Repair REMOVAL PROCEDURE 1. Remove the antenna by sliding it towards the front of the vehicle from the bracket in small increments. 2. Disconnect the coaxial cable from the antenna. 3. Remove the antenna from the bracket. INSTALLATION PROCEDURE 1. Install the antenna to the bracket in order to connect the coaxial cable. 2. Connect the coaxial cable to the antenna. 3. Slide the antenna until it clicks in place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Phone: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 11786 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 11791 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 11792 Global Positioning System Antenna: Technical Service Bulletins Onstar(R) - Antenna Coupling Revised Procedures File In Section: 08 - Body and Accessories Bulletin No.: 01-08-46-006A Date: December, 2001 SERVICE MANUAL UPDATE Subject: Revised OnStar(R) Antenna Coupling Replacement Procedures Models: 2000-2002 Passenger Cars and Trucks with Glass Mounted Antenna This bulletin is being revised to add the 2002 model year and revise the service procedures. Please discard Corporate Bulletin Number 01-08-46-006 (Section 08 - Body and Accessories). This bulletin is being issued to revise the OnStar(R) inner and outer antenna coupling replacement procedures in the Cellular Communication sub-section of the Body and Accessories section in the appropriate Service Manual. Please use the following to replace the existing information in the Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page in the Cellular Communication sub-section of the Service Manual. Coupling Replacement - Antenna Inner Removal Procedure Important: Use the described adhesion promoter to assure adequate bonding of the coupling to the glass. To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60°F) during the installation and for 6-8 hours immediately following the installation. Otherwise the new couplings may come off. Also, disregard the drying or curing time information listed in the instructions included in the replacement antenna coupling kits. In the near future, those instructions will be updated with the drying or curing times listed in this bulletin. ^ Do not attempt to reinstall the original cellular couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Disconnect the coaxial cable from the inner coupling of the mobile communication antenna. Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. Use a small, wide-bladed plastic tool to cut the double back tape material while lifting up on the inner antenna coupling. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 11793 1. Clean the inside of the glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. Important: The glass adhesion promoter described in the next step must be used to ensure a bonding of the coupling to the glass surface. Failure to use the described adhesion promoter may result in the coupling coming off the glass. 3. Apply Glass Adhesion Promoter, P/N 12378555 (in Canada, use P/N 88901239), to the glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. Important: ^ On rear backglass applications the RF connections for the inner antenna coupling should run parallel to the defogger gridline. ^ Align the inner and the outer antenna couplings. ^ Do not touch the adhesive backing on the antenna coupling. 4. Remove the protective film from the adhesive backing on the inner antenna coupling. 5. Align the inner antenna coupling to the existing exterior coupling. 6. Press firmly on all 4 corners and on the center of the antenna inner coupling (2) in order to ensure proper adhesion to the glass (4). Hold pressure on the inner coupling (2) for 10 to 30 seconds. 7. Ensure that no gaps occur between the couplings (5, 2) and the glass (4). 8. Connect the coaxial cable to the inner coupling (2). 9. Keep the vehicle dry. Allow 6 to 8 hours, at 15°C (60° F), for the adhesive to cure after installation. Coupling Replacement - Antenna Outer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 11794 Removal Procedure Important: Use the described adhesion promoter to assure adequate bonding of the coupling to the glass. To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60° F) during the installation and for the 6-8 hours immediately following the installation. Otherwise the new couplings may come off. Also, disregard the drying or curing time information listed in the instructions included in the replacement antenna coupling kits. In the near future, those instructions will be updated with the drying or curing times listed in this bulletin. ^ Do not attempt to reinstall the original cellular couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Install the inner coupling first if both the inner and the outer coupling are to be replaced. Refer to Coupling Replacement - Antenna Inner. Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. 2. Use a small, wide-bladed plastic tool to cut the double back tape material while lifting up on the outer antenna coupling. Installation Procedure 1. Clean the glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. Important: The glass adhesion promoter described in the next step must be used to ensure a bonding of the coupling to the glass surface. Failure to use the described adhesion promoter may result in the coupling coming off the glass. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 11795 3. Apply Glass Adhesion Promoter, P/N 12378555 (in Canada, use P/N 88901239), to the glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. Important: ^ Align the outer antenna coupling with the inner coupling. ^ Do not touch the adhesive backing on the antenna coupling. 4. Remove the protective film from the adhesive backing on the outer antenna coupling. 5. Align the outer antenna coupling to the inner antenna coupling. 6. Press firmly on all 4 corners and on the center of the outer antenna coupling (5) in order to ensure proper adhesion to the glass (4). Hold pressure on the outer coupling (5) for 10 to 30 seconds. 7. Ensure that no gaps occur between the couplings (5, 2) and the glass (4). 8. Keep the vehicle dry. Allow 6 to 8 hours, at 15°C (60°F), for the adhesive to cure after installation. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Extension Cable Replacement Antenna Cable: Service and Repair Antenna Extension Cable Replacement REMOVAL PROCEDURE 1. Remove the instrument panel trim panel. 2. Disconnect the extension cable from the radio. 3. Disconnect the extension cable from the HVAC duct. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Extension Cable Replacement > Page 11801 4. Disconnect the extension cable from the antenna. INSTALLATION PROCEDURE 1. Connect the extension cable to the radio. 2. Connect the extension cable to the HVAC duct. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Extension Cable Replacement > Page 11802 3. Connect the extension cable to the antenna. 4. Install the instrument panel trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Extension Cable Replacement > Page 11803 Antenna Cable: Service and Repair Radio Antenna Module Cable Replacement (Between Both Modules) REMOVAL PROCEDURE 1. Lower the rear of the headliner. Refer to Headliner Replacement. 2. Remove the cable connector from the radio control module (3). 3. Remove the cable connector from the radio antenna module (2). 4. Remove cable from the roof cross member by removing the cable retainer clips (1). 5. Remove the cable from the vehicle. INSTALLATION PROCEDURE 1. Install the cable to the roof cross member by pushing in the retainer clips (1). 2. Connect the cable connector to the radio antenna module (2). 3. Connect the cable connector to the radio control module (3). 4. Install the headliner. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Extension Cable Replacement > Page 11804 Antenna Cable: Service and Repair Radio Antenna Module Cable Replacement (From Radio to Module) REMOVAL PROCEDURE 1. Remove the IP trim panel. 2. Lower the headliner. 3. Loosen the bolt retaining the radio antenna module in order to disconnect the electrical connector. 4. Disconnect the cable (2) from the radio antenna module. 5. Remove the cable clips (1) from the roof. 6. Remove the cable clips (1) from the A-pillar. 7. Disconnect the cable (3) from the radio. 8. Disconnect the electrical wire connector (4). 9. Remove the radio cable from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Extension Cable Replacement > Page 11805 1. Install the cable clips (1) to the A-pillar. 2. Connect the electrical wire connector (4). 3. Connect the cable (3) to the radio. 4. Install the cable clips (1) to the roof. 5. Connect the cable (2) to the radio antenna module. 6. Connect the wire connector to the radio antenna module. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the bolt retaining the radio antenna module to the roof. Tighten Tighten the retaining bolt to 9 N.m (80 lb in). 8. Install the headliner. 9. Install the IP trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 11810 Theft Deterrent Control Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 11811 Alarm Module: Service and Repair THEFT DETERRENT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR. Refer to Disabling the SIR System in Restraint Systems. 2. Remove the steering column trim covers. 3. Remove the ignition lock cylinder. 4. Remove the theft deterrent control module wiring harness from the steering column harness. 5. Disconnect the electrical connector from the theft deterrent control module. 6. If, necessary, disconnect the electrical connector from the ignition lock cylinder case. 7. Remove the theft deterrent module (2) away from the lock cylinder housing (1). INSTALLATION PROCEDURE 1. Install the theft deterrent control module (2), onto the lock cylinder housing (1). 2. Install the theft deterrent control module wiring harness to the steering column harness. 3. If, necessary, disconnect the electrical connector from the ignition lock cylinder case. 4. Connect the electrical connector. 5. Install the ignition lock cylinder. 6. Install the steering column trim covers. 7. Enable the SIR system. Refer to Enabling the SIR System in Restraint Systems. 8. Program the new theft deterrent control module. Refer to Programming Theft Deterrent System Components. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 11816 Remote Control Door Lock Receiver (RCDLR) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 11817 Keyless Entry Receiver: Service and Repair REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel (IP) top cover. 2. Remove the module. Unsnap the 2 look arms. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the module starting with the large tang-tilt. Snap the 2 lock arms into the square holes. 3. Install the instrument panel (IP) top cover. 4. Program the transmitter. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE Under normal use, the battery in the transmitter will last about 2 years. For battery replacement, use a Panasonic 3 volt, type CR2032, or equivalent. 1. Open the transmitter case and perform the following steps: 1.1. Insert a dime between the 2 halves of the transmitter near the key ring hole. 1.2. Twist the dime. 2. Remove the battery. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair > Page 11822 1. Install the battery with the (+) positive side down. 2. Close the transmitter case and perform the following steps: 2.1. Align the top and bottom covers. 2.2. Press together the top and the bottom covers. 2.3. Inspect the operation of the transmitter. 3. Synchronize the transmitter. Refer to Transmitter Synchronization. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams Passlock Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Diagrams Cellular Telephone Microphone Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Diagrams Parking Assist Control Module: Diagrams Rear Object Sensor Control Module Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Diagrams > Page 11834 Rear Object Sensor Control Module Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Diagrams > Page 11835 Parking Assist Control Module: Service and Repair REMOVAL PROCEDURE 1. Lift the right rear seating surface up to gain access to the rear parking aid module. 2. Disconnect the electrical connector from the module. 3. Remove the module retainer. 4. Remove the module from the seat frame. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the module to the seat frame. Tighten Tighten the module retainer to 1.7 N.m (15 lb in). 2. Connect the electrical connector. 3. Lower the seating surface. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams Parking Assist Distance Sensor: Diagrams Object Sensor - LR Corner Object Sensor - RR Corner Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 11839 Object Sensor - LR Middle Object Sensor - RR Middle Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 11840 Parking Assist Distance Sensor: Service and Repair REAR OBJECT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connectors to the rear object sensor. 2. Lift the locking tabs on the housing (4) and remove the rear object sensor (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 11841 3. Insert a small size screw driver at (3) to release the tabs in order to remove the spring (1). 4. From the inside of the housing push in the tabs and remove. 5. Remove the bezel by pushing it through the fascia. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 11842 IMPORTANT: Do not paint the sensor. 1. Paint the sensor bezel to match the color of the bumper fascia. 2. Align the keyhole (2) with the key (1) and press the sensor bezel into the fascia. 3. Install the housing to the bezel through the back side of the fascia. The housing snaps into the cutouts on the bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 11843 IMPORTANT: The spring keys must be on the top and bottom of the housing. 4. Install the spring (1) to the housing (2) until fully seated. Ensure the sensor is held to the bumper fascia firmly. 5. Install the decoupling ring (2) to the sensor (1). 6. Insert the sensor into the housing (4) with the connector pointing toward the passenger side of the fascia. The sensor tabs snap into the cutouts on the housing (4). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 11844 7. Connect the electrical connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Locations > Page 11848 Rear Parking Assist (RPA) Disable Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Locations > Page 11849 Parking Assist Switch: Service and Repair REAR OBJECT ALARM MODULE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the dash trim bezel. 2. Grasp the buttons assembly (2) housing and pull outwards. 3. Disconnect the electrical connector from the rear object alarm module switch. 4. Remove the switch (1) from the housing (2). INSTALLATION PROCEDURE 1. Install the rear object alarm switch into the housing (2). 2. Connect the electrical connector to the switch (1). 3. Install the switch housing into the dash. 4. Install the dash trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams Driver Information Center (DIC) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Page 11853 Driver/Vehicle Information Display: Service and Repair REMOVAL PROCEDURE 1. Remove the rear quarter garnish molding. 2. Disconnect the electrical connector. 3. Remove the retaining screws (1). INSTALLATION PROCEDURE 1. Install the information center telltale assembly to the garnish molding. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screws (1). Tighten Tighten the retaining screws to 2 N.m (18 lb in). 3. Install the rear quarter garnish molding. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11862 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11863 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11864 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11865 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11866 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11867 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11868 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11869 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11870 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11871 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11872 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11873 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11874 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11875 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11876 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11877 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11878 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11879 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11880 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11881 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11882 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11883 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11884 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11885 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11886 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11887 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11888 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11889 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11890 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11891 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11892 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11893 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11894 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11895 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 11901 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 11906 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 11911 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 11912 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 11918 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11927 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11928 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11929 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11930 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11931 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11932 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11933 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11934 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11935 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11936 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11937 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11938 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11939 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11940 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11941 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11942 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11943 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11944 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11945 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11946 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11947 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11948 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11949 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11950 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11951 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11952 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11953 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11954 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11955 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11956 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11957 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11958 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11959 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 11960 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-64-007A > Sep > 08 > OnStar(R) - Analog Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 11977 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 11982 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 11983 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-007 > Dec > 06 > OnStar - Analog-Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 11993 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-64-007A > Sep > 08 > OnStar(R) - Analog Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 12014 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 12019 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 12020 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-007 > Dec > 06 > OnStar - Analog-Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12034 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12035 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12036 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12037 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12038 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12039 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12040 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12041 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12042 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12043 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12044 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12045 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12046 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12047 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12048 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12049 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12050 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12051 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12052 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12053 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12054 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12055 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12056 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12057 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12058 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12059 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12060 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12061 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12062 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12063 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12064 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12065 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12066 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12067 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Headphones / Earphones > Component Information > Technical Service Bulletins > Entertainment System - Headphone Foam Pad Replacement Headphones / Earphones: Technical Service Bulletins Entertainment System - Headphone Foam Pad Replacement Bulletin No.: 05-08-44-005A Date: July 19, 2007 INFORMATION Subject: Information on Rear Seat Headphone Foam Ear Pad Replacement if Worn or Damaged Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2, H3 2005-2008 Saab 9-7X with Rear Seat Entertainment System (RPOs U32, U42) Supercede: This bulletin is being revised to add models and model years and update the shipping costs. Please discard Corporate Bulletin Number 05-08-44-005 (Section 08 - Body and Accessories). Foam ear pads on the rear headphone may become worn or damaged. The headphone foam ear pads may wear out when not handled and stored carefully. If the headphone foam ear pads become damaged or worn out, the foam pads can be replaced separately from the headphone set. It is not necessary to replace the complete headphone set. Parts Information All pricing information listed in this bulletin is in U.S. dollars and is subject to change without notice. The headphone replacement foam ear pads can be ordered in pairs directly through the supplier. Have your customer call Unwired at 1-888-293-3332, then prompt zero (0). The replacement, P/N CS-980 (thick earfoam), can be ordered for $3.50 (USD) per pair plus $2.50 USPS shipping. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Garage Door Opener Transmitter: > 01-08-97-002 > Nov > 01 > HomeLink(R) Transmitter - Programming Difficulties Garage Door Opener Transmitter: Customer Interest HomeLink(R) Transmitter - Programming Difficulties File In Section: 08 - Body and Accessories Bulletin No.: 01-08-97-002 Date: November, 2001 INFORMATION Subject: Programming the HomeLink(R) Transmitter Models: 2000-2002 Passenger Cars and Light Duty Trucks with Universal Garage Door Opener (RPO UG1) If you have customers that are having difficulties programming their HomeLink(R) transmitter, you may suggest the following options: ^ The customer may contact HomeLink(R) directly at 1-800-355-3515 for assistance. Assistance is available in English, French and Spanish languages. ^ The customer may also be directed to the HomeLink(R) website at www.homelink.com. The website is user-friendly and actively demonstrates how to program the transmitter. Many newer garage door openers have a "rolling code" feature and the website does a great job of guiding the owner through the entire programming process. The HomeLink(R) phone number, website address, and other useful information can also be found in Section 2 of the Owner's Manual under HomeLink(R) Transmitter. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Garage Door Opener Transmitter: > 01-08-97-002 > Nov > 01 > HomeLink(R) Transmitter - Programming Difficulties Garage Door Opener Transmitter: All Technical Service Bulletins HomeLink(R) Transmitter Programming Difficulties File In Section: 08 - Body and Accessories Bulletin No.: 01-08-97-002 Date: November, 2001 INFORMATION Subject: Programming the HomeLink(R) Transmitter Models: 2000-2002 Passenger Cars and Light Duty Trucks with Universal Garage Door Opener (RPO UG1) If you have customers that are having difficulties programming their HomeLink(R) transmitter, you may suggest the following options: ^ The customer may contact HomeLink(R) directly at 1-800-355-3515 for assistance. Assistance is available in English, French and Spanish languages. ^ The customer may also be directed to the HomeLink(R) website at www.homelink.com. The website is user-friendly and actively demonstrates how to program the transmitter. Many newer garage door openers have a "rolling code" feature and the website does a great job of guiding the owner through the entire programming process. The HomeLink(R) phone number, website address, and other useful information can also be found in Section 2 of the Owner's Manual under HomeLink(R) Transmitter. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Technical Service Bulletins > Page 12102 Faster Tightening Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Technical Service Bulletins > Page 12103 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions Garage Door Opener Transmitter: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12106 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12107 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12108 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12109 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12110 Garage Door Opener Transmitter: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12111 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12112 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12113 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12114 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12115 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12116 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12117 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12118 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12119 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12120 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12121 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12122 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12123 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12124 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12125 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12126 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12127 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12128 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12129 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12130 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12131 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12132 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12133 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12134 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12135 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12136 Garage Door Opener Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12137 Garage Door Opener Schematics Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Page 12138 Garage Door Opener Transmitter: Description and Operation The garage door opener is located in the overhead console. The valet switch provides battery voltage to the garage door opener. If battery voltage is lost due to a condition such as a dead battery, the garage door opener unit relies on the non-servicable internal power backup supply. The unit is programmed using the customer's hand-held transmitters for the garage doors, electric entrance gates, or lighting and security systems. The garage door opener is rolling code capable. Rolling code is a system that allows the code that the customers receiver receives from the garage door opener to change every time the garage door opener is used within operating range of the receiver. When the receiver and the garage door opener are initially programmed together, a code is established, a new code is created for every new transmission. The software in the receiver recognizes the garage door opener and accepts the new code. The garage door opener is compatible with most, but not all types and brands of transmitters. If a problem should occur with a compatibility conflict with a transmitter, call HomeLinkTM at 1-800-355-3515. The garage door opener is a transmitter operating between 288-399 MHz. The power and range of the transmitter is limited to comply with laws governing the generation of Radio Frequency Interference (RFI). The transmitter is programmed by the user to accept the signal generated by the user's transmitters, refer to Garage Door Opener Programming - Universal. The garage door opener has 3 buttons that may be programmed for individual transmitter/receiver combinations to control up to 3 garage door openers, security gates, and lighting systems. Each button represents a transmitter code of the transmitter, which operates separately from any other button, and may be considered a separate transmitter. Operation consists of simply pressing a button to activate the corresponding transmitter. Battery voltage is provided to the garage door opener from the IGN SEN fuse in the IP fuse block. The garage door opener is grounded through G400. Inadvertent power is supplied from the body control module (BCM). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Garage Door Opener Transmitter: Symptom Related Diagnostic Procedures - Symptoms - Garage Door Opener IMPORTANT: Review the system description and operation in order to familiarize yourself with the system functions. Refer to Garage Door Opener Description and Operation. Visual/Physical Inspection ^ Inspect for aftermarket devices which could affect the operation of the garage door opener. Refer to Checking Aftermarket Accessories in Diagnostic Aids. ^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in Diagnostic Aids. Symptom List Refer to Garage Door Opener Inoperative in order to diagnose the symptom. Garage Door Opener Inoperative Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 12141 Steps 1-10 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement Garage Door Opener Transmitter: Service and Repair Garage Door Opener Replacement REMOVAL PROCEDURE 1. Remove the console roof screw. 2. Disconnect the electrical connectors. 3. Remove the console from vehicle. 4. Disconnect the electrical connector from the garage door opener. 5. Remove the garage door opener retaining screws. 6. Remove the garage door opener from the overhead console. INSTALLATION PROCEDURE 1. Install the garage door opener to the overhead console. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the garage door opener retaining screws. Tighten Tighten the retaining screws to 2 N.m (18 lb in). 3. Connect the electrical connector to the garage door opener. 4. Install the console to the roof. 5. Connect the electrical connectors. 6. Install the overhead console retaining screw. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement > Page 12144 Tighten Tighten the overhead console retaining screw to 2 N.m (18 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement > Page 12145 Garage Door Opener Transmitter: Service and Repair Garage Door Opener Programming Universal GARAGE DOOR OPENER PROGRAMMING IMPORTANT: Do not use the garage door opener (GDO) with any garage door opener that does not have the stop and reverse safety feature. This includes any garage door opener model manufactured before April 1,1982. Be sure that people and objects are clear of the garage door you are programming. The GDO is programmed by using the customer's hand-held transmitter(s). Turn the ignition OFF while programming the GDO transmitter. Follow these steps to program up to 3 channels: 1. If you have previously programmed a transmitter, proceed to Step 2. Otherwise, hold down the 2 outside buttons on the GDO transmitter for approximately 20 seconds, until the light on the GDO transmitter begins to flash rapidly. Then release the buttons. This procedure erases any previous settings and initializes the memory for all 3 channels. 2. Decide which of the 3 channels you want to program to the transmitter you have. 3. Hold the end of the hand-held transmitter against the front surface of the GDO (less than 1 inch) so you can still see the light. 4. Using both hands, press the hand-held transmitter button and the desired button on the GDO transmitter. Continue to hold both buttons through Step 5. IMPORTANT: The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLinkTM at 1-800-355-3515 in order to address this problem. 5. Hold down the buttons on both transmitters until you see the light on the GDO transmitter flash slowly and then rapidly. The rapid flashing, which could take up to 90 seconds, indicates that the GDO transmitter has been programmed. Release the buttons on both transmitters when the light starts to flash rapidly. TRAINING THE GDO FOR ROLLING CODE RECEIVERS This procedure is for training the customer's rolling code garage door openers to their GDO transmitter. The GDO must already be programmed to its hand-held transmitter. The training process below must be completed within 30 seconds or it must be repeated. 1. Locate the train button on the garage door opener receiver. Refer to the operator's manual for the garage door opener (or call HomeLinkTM at 1-800-355-3515 for assistance). Follow instructions for the garage door opener in order to determine when the unit is in train mode. 2. Return to the GDO transmitter in the vehicle, and press the button that you want trained for rolling codes 3 times, for 1 second each time. 3. Press the button used again in order to verify that the GDO transmitter has been programmed. You may use either the hand-held transmitter or the GDO to open the garage door. The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLinkTM at 1-800-355-3515 in order to address compatibility concerns. ERASING CHANNELS To erase programmed channels, hold down the 2 outside buttons until the light on the GDO transmitter begins to flash. Individual channels cannot be erased, but can be reprogrammed using the Garage Door Opener Programming and the Training GDO for Rolling Code Receivers procedures. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement > Page 12146 Non-Compatible Garage Door Openers NON-COMPATIBLE GARAGE DOOR OPENERS Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Page 12147 Special Tools And Equipment Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 12153 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 12154 Global Positioning System Antenna: Technical Service Bulletins Onstar(R) - Antenna Coupling Revised Procedures File In Section: 08 - Body and Accessories Bulletin No.: 01-08-46-006A Date: December, 2001 SERVICE MANUAL UPDATE Subject: Revised OnStar(R) Antenna Coupling Replacement Procedures Models: 2000-2002 Passenger Cars and Trucks with Glass Mounted Antenna This bulletin is being revised to add the 2002 model year and revise the service procedures. Please discard Corporate Bulletin Number 01-08-46-006 (Section 08 - Body and Accessories). This bulletin is being issued to revise the OnStar(R) inner and outer antenna coupling replacement procedures in the Cellular Communication sub-section of the Body and Accessories section in the appropriate Service Manual. Please use the following to replace the existing information in the Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page in the Cellular Communication sub-section of the Service Manual. Coupling Replacement - Antenna Inner Removal Procedure Important: Use the described adhesion promoter to assure adequate bonding of the coupling to the glass. To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60°F) during the installation and for 6-8 hours immediately following the installation. Otherwise the new couplings may come off. Also, disregard the drying or curing time information listed in the instructions included in the replacement antenna coupling kits. In the near future, those instructions will be updated with the drying or curing times listed in this bulletin. ^ Do not attempt to reinstall the original cellular couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Disconnect the coaxial cable from the inner coupling of the mobile communication antenna. Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. Use a small, wide-bladed plastic tool to cut the double back tape material while lifting up on the inner antenna coupling. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 12155 1. Clean the inside of the glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. Important: The glass adhesion promoter described in the next step must be used to ensure a bonding of the coupling to the glass surface. Failure to use the described adhesion promoter may result in the coupling coming off the glass. 3. Apply Glass Adhesion Promoter, P/N 12378555 (in Canada, use P/N 88901239), to the glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. Important: ^ On rear backglass applications the RF connections for the inner antenna coupling should run parallel to the defogger gridline. ^ Align the inner and the outer antenna couplings. ^ Do not touch the adhesive backing on the antenna coupling. 4. Remove the protective film from the adhesive backing on the inner antenna coupling. 5. Align the inner antenna coupling to the existing exterior coupling. 6. Press firmly on all 4 corners and on the center of the antenna inner coupling (2) in order to ensure proper adhesion to the glass (4). Hold pressure on the inner coupling (2) for 10 to 30 seconds. 7. Ensure that no gaps occur between the couplings (5, 2) and the glass (4). 8. Connect the coaxial cable to the inner coupling (2). 9. Keep the vehicle dry. Allow 6 to 8 hours, at 15°C (60° F), for the adhesive to cure after installation. Coupling Replacement - Antenna Outer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 12156 Removal Procedure Important: Use the described adhesion promoter to assure adequate bonding of the coupling to the glass. To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60° F) during the installation and for the 6-8 hours immediately following the installation. Otherwise the new couplings may come off. Also, disregard the drying or curing time information listed in the instructions included in the replacement antenna coupling kits. In the near future, those instructions will be updated with the drying or curing times listed in this bulletin. ^ Do not attempt to reinstall the original cellular couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Install the inner coupling first if both the inner and the outer coupling are to be replaced. Refer to Coupling Replacement - Antenna Inner. Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. 2. Use a small, wide-bladed plastic tool to cut the double back tape material while lifting up on the outer antenna coupling. Installation Procedure 1. Clean the glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. Important: The glass adhesion promoter described in the next step must be used to ensure a bonding of the coupling to the glass surface. Failure to use the described adhesion promoter may result in the coupling coming off the glass. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 12157 3. Apply Glass Adhesion Promoter, P/N 12378555 (in Canada, use P/N 88901239), to the glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. Important: ^ Align the outer antenna coupling with the inner coupling. ^ Do not touch the adhesive backing on the antenna coupling. 4. Remove the protective film from the adhesive backing on the outer antenna coupling. 5. Align the outer antenna coupling to the inner antenna coupling. 6. Press firmly on all 4 corners and on the center of the outer antenna coupling (5) in order to ensure proper adhesion to the glass (4). Hold pressure on the outer coupling (5) for 10 to 30 seconds. 7. Ensure that no gaps occur between the couplings (5, 2) and the glass (4). 8. Keep the vehicle dry. Allow 6 to 8 hours, at 15°C (60°F), for the adhesive to cure after installation. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > Service Manual - Revised OnStar(R) VIU & VCU Replacement Global Positioning System Module: Technical Service Bulletins Service Manual - Revised OnStar(R) VIU & VCU Replacement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-46-011 Date: September, 2002 SERVICE MANUAL UPDATE Subject: Revised OnStar(R) Vehicle Interface Unit (VIU) Replacement and OnStar(R) Vehicle Communication Unit (VCU) Replacement Reconfiguration Procedure Models: 2001-2002 Buick LeSabre, Park Avenue 2002 Buick Rendezvous 2001 Cadillac Catera, DeVille, Seville 2001-2002 Cadillac Eldorado 2001 Chevrolet Blazer, Impala, Monte Carlo 2001-2002 Chevrolet Silverado, Suburban, Tahoe, Venture 2001 GMC Envoy, Jimmy 2001-2002 GMC Sierra, Yukon, Yukon XL 2001 Oldsmobile Bravada, Intrigue 2001-2002 Oldsmobile Aurora, Silhouette 2001-2002 Pontiac Aztek, Bonneville, Grand Prix, Montana with Generation 3 OnStar(R) (RPO UE1) This bulletin is being issued to revise the reconfiguration procedure found in the OnStar(R) Vehicle Interface Unit (VIU) Replacement and the OnStar(R) Vehicle Communication Unit (VCU) Replacement procedures in the Cellular Communication sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Due to a new process for configuring replacement Generation 3 (formerly 2.6) OnStar(R) modules for the OnStar(R) Personal Calling feature, vehicles equipped with this version of the system will require a revised OnStar(R) Reconfiguration procedure in the event of module replacement. In addition, the Station Identification Number (STID) and Electronic Serial Number (ESN) numbers are currently accessible by means of the scan tool The procedures for both the Vehicle Interface Unit and Vehicle Communication Unit differ only in which number (STID or ESN) is recorded and transferred to the OnStar(R) Call Center. Important: After replacing the VIU or VCU, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. 1. Press and hold the white Dot button until the OnStar(R) status LED turns from green to red, and back again to green. 2. Install a scan tool. Use the ID information menu to access the new STID (VIU) or ESN (VCU) number. 3. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 4. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center. Tell the advisor that this vehicle has received a new VIU or VCU and ask the advisor to perform the following procedure: 5. Add the new STID (VIU) or ESN (VCU) to update the customer's account. 6. Follow any additional instructions from the OnStar(R) advisor. 7. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > Service Manual - Revised OnStar(R) VIU & VCU Replacement > Page 12162 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > Service Manual - Revised OnStar(R) VIU & VCU Replacement Navigation Module: Technical Service Bulletins Service Manual - Revised OnStar(R) VIU & VCU Replacement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-46-011 Date: September, 2002 SERVICE MANUAL UPDATE Subject: Revised OnStar(R) Vehicle Interface Unit (VIU) Replacement and OnStar(R) Vehicle Communication Unit (VCU) Replacement Reconfiguration Procedure Models: 2001-2002 Buick LeSabre, Park Avenue 2002 Buick Rendezvous 2001 Cadillac Catera, DeVille, Seville 2001-2002 Cadillac Eldorado 2001 Chevrolet Blazer, Impala, Monte Carlo 2001-2002 Chevrolet Silverado, Suburban, Tahoe, Venture 2001 GMC Envoy, Jimmy 2001-2002 GMC Sierra, Yukon, Yukon XL 2001 Oldsmobile Bravada, Intrigue 2001-2002 Oldsmobile Aurora, Silhouette 2001-2002 Pontiac Aztek, Bonneville, Grand Prix, Montana with Generation 3 OnStar(R) (RPO UE1) This bulletin is being issued to revise the reconfiguration procedure found in the OnStar(R) Vehicle Interface Unit (VIU) Replacement and the OnStar(R) Vehicle Communication Unit (VCU) Replacement procedures in the Cellular Communication sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Due to a new process for configuring replacement Generation 3 (formerly 2.6) OnStar(R) modules for the OnStar(R) Personal Calling feature, vehicles equipped with this version of the system will require a revised OnStar(R) Reconfiguration procedure in the event of module replacement. In addition, the Station Identification Number (STID) and Electronic Serial Number (ESN) numbers are currently accessible by means of the scan tool The procedures for both the Vehicle Interface Unit and Vehicle Communication Unit differ only in which number (STID or ESN) is recorded and transferred to the OnStar(R) Call Center. Important: After replacing the VIU or VCU, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. 1. Press and hold the white Dot button until the OnStar(R) status LED turns from green to red, and back again to green. 2. Install a scan tool. Use the ID information menu to access the new STID (VIU) or ESN (VCU) number. 3. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 4. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center. Tell the advisor that this vehicle has received a new VIU or VCU and ask the advisor to perform the following procedure: 5. Add the new STID (VIU) or ESN (VCU) to update the customer's account. 6. Follow any additional instructions from the OnStar(R) advisor. 7. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > Service Manual - Revised OnStar(R) VIU & VCU Replacement > Page 12168 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Uplevel Amplifier: Diagrams Uplevel Audio Amplifier C - 1 (Uplevel) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Uplevel > Page 12174 C - 2 Audio Amplifier (Uplevel) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Uplevel > Page 12175 Amplifier: Diagrams Luxury Audio Amplifier - C1 (Luxury) Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Uplevel > Page 12176 Audio Amplifier - C1 (Luxury) Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Uplevel > Page 12177 Audio Amplifier - C2 (Luxury) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 12178 Amplifier: Service and Repair REMOVAL PROCEDURE 1. Lower the glove box. 2. Disconnect the electrical connectors. 3. Use the following steps in order to remove the amplifier from the bracket: 3.1. Push the retention clip upward and in. 3.2. Rotate the amplifier. 3.3. Push the amplifier up in order to clear the amplifier mounting bracket and the HVAC module. 3.4. Remove the amplifier. INSTALLATION PROCEDURE 1. Connect the amplifier to the bracket by clipping the amplifier into place. 2. Connect the electrical connectors 3. Inspect the system operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams Remote Playback Device - CD Player Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Playing a Compact Disc - Uplevel/Luxury Compact Disc Player (CD): Description and Operation Playing a Compact Disc - Uplevel/Luxury PWR 1. Press the PWR knob in order to turn the system on. 2. The system can be turned on by inserting a compact disc into the player with the ignition in the ON position. 3. Insert a disc partway into the slot, label side up. 4. The player pulls the disc in. 5. When inserted, the disc will begin playing track 1. 6. Wait a few seconds until the disc plays. 7. The letters "CD" and a CD symbol appears on the display. 8. If the disc comes back out and ERR appears on the display, inspect for the following conditions: ^ The disc is upside down. ^ The disc is dirty, scratched, or wet. ^ There is too much moisture in the air. Wait an hour and try again. ^ The vehicle is operating on a very rough road. ^ The disc player is very hot. 9. Press RECALL in order to eliminate the ERR message. RECALL 1. Press the RECALL button in order to see what track is playing. 2. Press the RECALL button again within 5 seconds in order to see the elapsed time of the current track. 3. The track number appears when a new track begins to play. 4. Press RECALL again in order to return to the time display. PREV 1. Press PREV or the SEEK left arrow in order to search for the previous selection. 2. If you hold the PREV button or press it more than once, the disc advances further. RDM 1. The random playback (RDM) feature allows the tracks on the compact disc to be played in random order rather than in sequential order. 2. During random playback, a RANDOM indicator appears in the display. 3. Press RDM again in order to return to normal play. NEXT 1. Press NEXT or the SEEK right arrow in order to search for the next selection. 2. If you hold the NEXT button or press it more than once, the disc will advance further. 3. The next track number will appears on the display. REV 1. Press and hold the REV button in order to quickly reverse within a track. 2. When the CD reverses, elapsed time displays in order to find the correct passage. FWD 1. Press and hold the FWD button in order to quickly advance within a track. 2. When the CD advances, elapsed time displays in order to find the correct passage. AM-FM 1. While in the CD mode, press the AM-FM button in order to stop playing the CD and play the radio. 2. The CD symbol will still be displayed but the letters CD are replaced with AM, FM1, or FM2. 3. If the radio is turned OFF, the disc will remain in the player and resume playing at the point where it stopped, when the radio is turned ON. CD AUX 1. Press the CD AUX button in order to return from listening to the radio and play the CD. 2. When a disc plays, the letters "CD" and the CD symbol will appear on the display. 3. If the radio is turned OFF, the disc will remain in the player and resume playing at the point where it stopped, when the radio is turned ON. EJECT ^ Press EJECT in order to eject the disc from the CD player. ^ A disc that has been ejected but not removed from the player will be pulled back in within 30 seconds. ^ This protects the disc and the player from damage. ^ The disc does not play. ^ In order to remove the disc, press the EJECT button and remove the disc from the player. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Playing a Compact Disc - Uplevel/Luxury > Page 12184 Compact Disc Player (CD): Description and Operation Remote Playback Device - CD Player Uplevel/Luxury In order to operate the Compact Disc player, perform the following steps: 1. Insert a disk part way into the slot, label side up. 2. If the radio is in the OFF position and the ignition is in the ON position when you insert the CD, the radio turns on and begins playing the CD. 3. In order to load a CD with the ignition in the OFF position, press the EJECT button on the remote player and insert the disc. 4. In order to remove the disc, press the EJECT button and remove the disc. 5. All of the compact disc functions are controlled by the radio buttons except EJECT. 6. When a disc is in the player, a CD symbol appears next to the CD symbol in the bottom left corner on the display. The track number will also be displayed. 7. If the disc comes back out and ERR appears on the display, inspect for the following conditions: ^ An upside down disc ^ A dirty, scratched, or wet disc ^ Too much moisture in the air If there is too much moisture in the air, wait about 1 hour and try again. ^ The vehicle is operating on a very rough road. TAPE AUX 1. With a disc loaded in the player and the radio playing, press the TAPE AUX button once in order to play the compact disc. 2. Press AM-FM in order to return to the radio. 3. If you load both a cassette and a CD, press TAPE AUX in order to switch between the tape and the compact disc. SEEK 1. Press the left arrow while playing a CD in order to go back to the beginning of the current track. 2. The CD goes back to the current track if more than 8 seconds have played. 3. Press the left arrow again in order to go to the previous tracks. 4. Press the right arrow in order to go to the next higher track on the disc. PREV 1. Press PREV in order to go back to the beginning of a current track. 2. The CD goes back to the current track after 8 seconds have played. 3. Press PREV again in order to go the previous track on the disc. PROG The PROG button functions only when the vehicle is equipped with a 12-disc changer. NEXT Press the NEXT button in order to advance to the next track on the disc. REV 1. Press and hold the REV button in order to quickly reverse within a track. 2. When the CD reverses, elapsed time displays in order to find the correct passage. FWD 1. Press and hold the FWD button in order to advance within a track. 2. When the CD advances, elapsed time displays in order to find the correct passage. RANDOM 1. Press PSCAN in order to enter the RANDOM play mode. RANDOM will appear on the display. 2. While in this mode, the tracks on the disc will be played in random order. 3. If you press the SEEK, PREV, or NEXT buttons while in the random mode, the PREV or NEXT track scans randomly. 4. Press PSCAN again in order to turn off RANDOM and return to normal operation. EJECT ^ Press EJECT in order to eject the disc from the CD player. ^ A disc that has been ejected but not removed from the player will be pulled back in within 30 seconds. This protects the disc and the player from damage. ^ The disc does not play. ^ In order to remove the disc, press the EJECT button and remove the disc from the player. RECALL 1. Press RECALL in order to see what track is playing. 2. Press RECALL again within 5 seconds in order to view elapsed time. 3. Press RECALL a third time and the time of day will be displayed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Playing a Compact Disc - Uplevel/Luxury > Page 12185 Compact Disc Player (CD): Description and Operation Remote Playback Device - In-dash CD Changer - Luxury The compact disc changer plays up to six standard size CDs continuously. Individual CDs may be loaded or ejected into or from any position. A green light on each numbered button indicates a CD is loaded in the respective position. An amber light on a numbered button indicates that a CD is playing. When loading CDs, the loading slot indicators turn amber to indicate that the player is ready to accept a CD. CDs can be loaded or ejected with the radio or the ignition being on or off. Loading A Single CD Use the following steps to load a single CD into the CD Changer: 1. Press the LOAD button. Available positions will blink amber. 2. Select a position by pressing the desired numbered button with the amber blinking light. If a button is not pressed within 5 seconds, the changer will go to the lowest available position. 3. Load the CD when the loading slot indicators turn amber. An internal door will open allowing a single CD to be inserted into the changer. After approximately 10 seconds the changer will be ready to play. Loading Multiple CDs Use the following steps to load multiple CDs into the CD Changer: 1. Press and hold the LOAD button. The first CD will be loaded into the lowest numbered empty position. 2. Load a single CD when the loading slot indicators turn amber. After about 10 seconds the changer will cycle to the next available position. 3. Repeat Step 2 until all CDs are loaded in to all of the desired positions. If you do not wish to load all of the positions, you can cancel the load all function by pressing a button with a green flashing indicator light or wait 20 seconds for the changer to time out. Ejecting CDs 1. To eject all CDs, Press and hold the eject button. To eject selected CDs, press the eject button. The buttons with loaded CDs will blink amber. 2. Press one of the amber blinking buttons to select the location of the CD you want to eject. The changer will move to that location and eject the CD. If you do not remove the CD from the player within ten seconds, it will be reloaded. If the eject button is pressed and a numbered location button is not pressed within 5 seconds, the current or last played CD will be ejected. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Playing a Compact Disc - Uplevel/Luxury > Page 12186 Compact Disc Player (CD): Description and Operation Playing the Remote Playback DeviceIn-dash CD Changer 1. Press the desired numbered button with a green indicator light. 2. Press the CD TAPE button on the radio. The CD changer will go to its last played position. Prev Press this button or the SEEK left arrow to go to the previous track if the current selection has been playing for less than 8 seconds. If the PREV button is pressed and the current selection has been playing for more than 8 seconds, it will go to the beginning of the current selection. If you hold or press this button more than once, the player will continue moving back through the CD. The sound will mute while seeking. Prog Press this button to select a CD. The CD number and track number will be displayed. Next Press this button or the SEEK right arrow to go to the next track. If you hold the button or press it more than once, the player will continue moving forward through the CD. The sound will mute while seeking. Rev Press and hold this button to reverse quickly through a track selection. Release it to resume playing. Fwd Press and hold this button to advance quickly through a track selection. Release it to resume playing. Seek Press the right arrow to seek to the next selection on the CD. Press the left arrow to search for the previous selection on the CD. The sound will mute while seeking. P.Scan Press this button to hear the tracks in random, rather than sequential, order. DSC will appear on the radio display, which will randomly play the tracks on the current CD. Press P.SCAN again to make the radio display ALL, which will randomly play all loaded CDs. Press P.SCAN again to turn off random play OFF will appear on the radio display. Cd Tape Press this button if you have a CD loaded into the changer and the radio is turned on, to play a CD. Press AM FM to return to the radio when a CD is playing. Press CD TAPE to switch between the tape and CD changer if all are loaded. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Page 12187 Compact Disc Player (CD): Service and Repair REMOTE CD PLAYER REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Do not grab or pull on the CD storage door when removing the trim bezel. 1. Remove the screws securing the trim bezel to the console extension. 2. Protect the console extension from damage then carefully use a small prying device to push in the tabs underneath the trim bezel securing the top of the trim bezel 3. Remove the trim bezel. 4. To remove the bezel on the luxury console, refer to Bezel Replacement - Floor Console (Luxury). 5. Use a small screwdriver in order to release the CD player retainers. 6. Slide the CD player out. 7. Disconnect the electrical connector. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Page 12188 1. Connect the electrical connector. 2. Install the CD player. 3. When the CD player is fully seated, snap the unit into the retainers. 4. Install the bezel on the luxury console. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the trim bezel and the screws. Tighten Tighten the screws to 2 N.m (15 lb in). 6. Verify the component operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-44-011 > Jun > 03 > Audio System Tweeter Rattles in Front Door(s) Speaker: Customer Interest Audio System - Tweeter Rattles in Front Door(s) Bulletin No.: 03-08-44-011 Date: June 27, 2003 TECHNICAL Subject: Tweeter Speaker Rattle in Front Side Door(s), Tweeter Speaker Falls Out of Position (Modify Door Trim Panel and/or Add Grommets and Replace Tweeter Speaker) Models: 1999-2003 Chevrolet Silverado Pickup Models 2000-2003 Chevrolet Tahoe, Suburban 2002-2003 Chevrolet Avalanche 1999-2003 GMC Sierra Pickup Models 2000-2003 GMC Yukon, Yukon XL with Uplevel Audio System (Non-Bose(R)) (RPO UQ3) Condition Some customers may comment on a rattle noise in either front side door or that the upper tweeter speaker has fallen out of position. Cause A material incompatibility between the door trim and the door tweeter speaker may cause this condition. Over time, the two posts used to attach the tweeter to the door trim may fracture. Correction New grommets have been released that will be placed over the tweeter speaker posts to isolate the two materials and correct this condition. Grommets will have to be attached to the current stock of tweeter part numbers. The new tweeters will have the two grommets already attached to the posts. Replace the tweeter speaker and add grommets as necessary. The door trim panel post holes for any tweeter part number will have to be slightly enlarged to accommodate the grommets. Use the following procedure and refer to the Parts Information for the applicable speaker parts/usage. 1. Remove the front door trim panel. Refer to the Trim Panel Replacement - Side Front Door procedure in the Doors sub-section of SI. 2. Remove the speaker grille. Refer to the Speaker Grille Replacement - Front Door procedure in the Entertainment sub-section of SI. 3. Remove the tweeter speaker retaining nuts. 4. Remove the speaker from the door trim panel. 5. Enlarge the two tweeter speaker mounting holes in the door trim panel to 9.525 mm (0.375 in) (3/8 in). This will accommodate the grommets. This Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-44-011 > Jun > 03 > Audio System Tweeter Rattles in Front Door(s) > Page 12202 step is required before the installation of any tweeter part number. 6. If replacement tweeter speaker P/N is 15772411 or 15071121, attach one grommet (3), P/N 15204327, to each of the speaker posts. 7. Position the speaker (4) into the opening in the door trim panel (2). 8. Install the tweeter speaker retaining nuts (1). Tighten Tighten to 1.6 N.m (14 lb in). 9. Install the speaker grille. Refer to the Speaker Grille Replacement - Front Door procedure in the Entertainment sub-section of SI. 10. Install the front door trim panel. Refer to the Trim Panel Replacement - Side Front Door procedure in the Doors sub-section of SI. Parts Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-44-011 > Jun > 03 > Audio System Tweeter Rattles in Front Door(s) > Page 12203 Parts are expected to be available 7-17-2003 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-08-44-011 > Jun > 03 > Audio System - Tweeter Rattles in Front Door(s) Speaker: All Technical Service Bulletins Audio System - Tweeter Rattles in Front Door(s) Bulletin No.: 03-08-44-011 Date: June 27, 2003 TECHNICAL Subject: Tweeter Speaker Rattle in Front Side Door(s), Tweeter Speaker Falls Out of Position (Modify Door Trim Panel and/or Add Grommets and Replace Tweeter Speaker) Models: 1999-2003 Chevrolet Silverado Pickup Models 2000-2003 Chevrolet Tahoe, Suburban 2002-2003 Chevrolet Avalanche 1999-2003 GMC Sierra Pickup Models 2000-2003 GMC Yukon, Yukon XL with Uplevel Audio System (Non-Bose(R)) (RPO UQ3) Condition Some customers may comment on a rattle noise in either front side door or that the upper tweeter speaker has fallen out of position. Cause A material incompatibility between the door trim and the door tweeter speaker may cause this condition. Over time, the two posts used to attach the tweeter to the door trim may fracture. Correction New grommets have been released that will be placed over the tweeter speaker posts to isolate the two materials and correct this condition. Grommets will have to be attached to the current stock of tweeter part numbers. The new tweeters will have the two grommets already attached to the posts. Replace the tweeter speaker and add grommets as necessary. The door trim panel post holes for any tweeter part number will have to be slightly enlarged to accommodate the grommets. Use the following procedure and refer to the Parts Information for the applicable speaker parts/usage. 1. Remove the front door trim panel. Refer to the Trim Panel Replacement - Side Front Door procedure in the Doors sub-section of SI. 2. Remove the speaker grille. Refer to the Speaker Grille Replacement - Front Door procedure in the Entertainment sub-section of SI. 3. Remove the tweeter speaker retaining nuts. 4. Remove the speaker from the door trim panel. 5. Enlarge the two tweeter speaker mounting holes in the door trim panel to 9.525 mm (0.375 in) (3/8 in). This will accommodate the grommets. This Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-08-44-011 > Jun > 03 > Audio System - Tweeter Rattles in Front Door(s) > Page 12209 step is required before the installation of any tweeter part number. 6. If replacement tweeter speaker P/N is 15772411 or 15071121, attach one grommet (3), P/N 15204327, to each of the speaker posts. 7. Position the speaker (4) into the opening in the door trim panel (2). 8. Install the tweeter speaker retaining nuts (1). Tighten Tighten to 1.6 N.m (14 lb in). 9. Install the speaker grille. Refer to the Speaker Grille Replacement - Front Door procedure in the Entertainment sub-section of SI. 10. Install the front door trim panel. Refer to the Trim Panel Replacement - Side Front Door procedure in the Doors sub-section of SI. Parts Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-08-44-011 > Jun > 03 > Audio System - Tweeter Rattles in Front Door(s) > Page 12210 Parts are expected to be available 7-17-2003 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speaker: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speaker: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speaker: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 12220 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speaker: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 12230 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Door Speaker LR Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Door Speaker LR > Page 12233 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Door Speaker LR > Page 12234 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Door Speaker LR > Page 12235 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Door Speaker LR > Page 12236 Speaker: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Door Speaker LR > Page 12237 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Door Speaker LR > Page 12238 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Door Speaker LR > Page 12239 Locations View Subwoofer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Door Speaker LR > Page 12240 Locations View For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Door Speaker LR > Page 12241 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions Speaker: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12244 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12245 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12246 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12247 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12248 Speaker: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12249 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12250 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12251 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12252 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12253 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12254 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12255 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12256 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12257 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12258 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12259 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12260 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12261 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12262 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12263 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12264 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12265 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12266 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12267 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12268 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12269 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12270 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12271 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12272 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12273 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12274 Speaker: Connector Views Speaker - Left A Pillar Tweeter (Luxury) Speaker - Left Console Tweeter (Luxury) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12275 Speaker - Left D Pillar Speaker - Left D Pillar Twiddler (Luxury) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12276 Speaker - LR Door Speaker - Right A Pillar Tweeter (Luxury) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12277 Speaker - Right Console Tweeter (Luxury) Speaker - Right D Pillar Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12278 Speaker - Right D Pillar Twiddler (Luxury) Speaker - RR Door Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12279 Speaker - Subwoofer Speaker - LF Door (Base) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12280 Speaker - LF Door Speaker - RF Door Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12281 Speaker: Electrical Diagrams Radio/Audio System Schematics: Speakers - Base Speakers - YE9 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12282 Radio/Audio System Schematics: Speakers - YE9 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Front Speakers - Y91 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12283 Radio/Audio System Schematics: Front Speakers - Y91 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Rear Speakers - Y91 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 12284 Radio/Audio System Schematics: Rear Speakers - Y91 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Base Level Speaker: Description and Operation Base Level BAL ^ Turn the BAL control knob behind the VOLUME knob to select more or less sound, distributed between the left or the right speakers. ^ The middle position will deliver an equal balance of sound between the left and right speakers. FADE ^ Turn the FADE control knob behind the TUNE knob to select more or less sound, distributed between the front and rear speakers. ^ The middle position will deliver an equal balance of sound between the front and rear speakers. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Base Level > Page 12287 Speaker: Description and Operation Uplevel/Luxury BALANCE 1. Depress the BAL control in order to remove the control from the recessed position. 2. Rotate the balance to the right in order to adjust the sound to the right speakers. 3. Rotate the balance to the left in order to adjust the sound to the left speakers. 4. Push the control knob back in to store when not in use. FADE 1. Depress the FADE control in order to remove the control from the recessed position. 2. Rotate the FADE control knob to the right in order to adjust the sound to the front speakers. 3. Rotate the FADE control knob to the left in order to adjust the sound to the rear speakers. 4. Push the control knob back in order to store when not in use. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Speaker: Symptom Related Diagnostic Procedures Steps 1-9 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 12290 Steps 1-6 Steps 1-7 Speakers Inoperative - One or More Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 12291 SCHEMATIC REFERENCE: RADIO/AUDIO SYSTEM SCHEMATICS PRELIMINARY INFORMATION Review the Radio/Audio Description and Operation and perform necessary inspections. Refer to Radio/Audio System Description and Operation IMPORTANT: The following information lists the most probable cause of the concern to the least probable cause. If the list leads to the replacement of a component, always inspect for a poor connection before proceeding with replacement. Refer to Testing for Intermittent and Poor Connections, and to Connector Repairs in Diagnostic Aids. ONE SPEAKER INOPERATIVE 1. Speaker output open. Test the appropriate speaker output circuits for an open. Refer to Circuit Testing, and to Wiring Repairs in Diagnostic Aids. 2. Audio output from the radio is not evident. Test for any AC voltage between the appropriate speaker output circuits at the speaker harness connector, disconnected with the radio volume adjusted to an audible level. If AC voltage is present, replace the speaker. For Front Door Refer to Speaker Replacement - Front Door for Rear Door refer to Speaker Replacement - Rear Door for Rear Pillar refer to Speaker Replacement Rear Pillar (Utility). If AC voltage is not present, replace the radio. Refer to Radio Replacement. ALL SPEAKERS INOPERATIVE 1. Speaker output shorted - Test all speaker outputs for a short. Refer to Circuit Testing, and to Wiring Repairs in Diagnostic Aids. 2. Faulty radio - Replace the radio. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 12292 Speaker Replacement Reference Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console (Tweeter) Speaker: Service and Repair Speaker Replacement - Front Floor Console (Tweeter) REMOVAL PROCEDURE 1. Remove the center console bezel. 2. Remove the speaker retaining nuts (1). 3. Disconnect the wire connector (2). 4. Remove the speaker from the console. INSTALLATION PROCEDURE 1. Install the speaker to the console. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Do not exceed torque specification. Over tightening of the nuts will result in the stud breaking from the console. 2. Install the retaining nuts. Tighten Tighten the retaining nuts to 0.7 N.m (6.2 lb in). 3. Connect the electrical connector (2). 4. Install the center console bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console (Tweeter) > Page 12295 Speaker: Service and Repair Speaker Replacement - Front Floor Console (806 Subwoofer) REMOVAL PROCEDURE 1. Remove the IP extension. 2. Disconnect the wire connector from the I/P extension to the console (1). 3. Move the I/P extension reward to gain access to the wire connector in front of the subwoofer speaker grill. 4. Disconnect the wire connector. 5. Ensure all wire harness are removed from the IP extension. 6. Remove the subwoofer assembly from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console (Tweeter) > Page 12296 1. Place the subwoofer assembly in the vehicle. 2. Route all wire harness in the IP extension. 3. Connect the wire connector in front of the subwoofer speaker grill. 4. Connect the wire connector (1). 5. Install the IP extension to the IR. 6. Ensure the proper operation of the subwoofer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console (Tweeter) > Page 12297 Speaker: Service and Repair Speaker Replacement - Front (Windshield Pillar Speaker) REMOVAL PROCEDURE 1. Remove the windshield garnish molding (2). 2. Disconnect the electrical connector (3) to the speaker. 3. Remove the speaker (1) by press until it is out of the molding. INSTALLATION PROCEDURE 1. Press in the speaker (1) until it is fully seated. 2. Connect the electrical connector (3). 3. Install the windshield garnish molding (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console (Tweeter) > Page 12298 Speaker: Service and Repair Speaker Replacement - Front Door REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the speaker by pushing down on the top retainer. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the speaker. Push the speaker into place. Ensure that the speaker is completely seated. 3. Install the trim panel. 4. Inspect the component operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console (Tweeter) > Page 12299 Speaker: Service and Repair Speaker Replacement - Front Floor Console (Tweeter) REMOVAL PROCEDURE 1. Remove the center console bezel. 2. Remove the speaker retaining nuts (1). 3. Disconnect the wire connector (2). 4. Remove the speaker from the console. INSTALLATION PROCEDURE 1. Install the speaker to the console. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Do not exceed torque specification. Over tightening of the nuts will result in the stud breaking from the console. 2. Install the retaining nuts. Tighten Tighten the retaining nuts to 0.7 N.m (6.2 lb in). 3. Connect the electrical connector (2). 4. Install the center console bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console (Tweeter) > Page 12300 Speaker Replacement - Front Floor Console (806 Subwoofer) REMOVAL PROCEDURE 1. Remove the IP extension. 2. Disconnect the wire connector from the I/P extension to the console (1). 3. Move the I/P extension reward to gain access to the wire connector in front of the subwoofer speaker grill. 4. Disconnect the wire connector. 5. Ensure all wire harness are removed from the IP extension. 6. Remove the subwoofer assembly from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console (Tweeter) > Page 12301 1. Place the subwoofer assembly in the vehicle. 2. Route all wire harness in the IP extension. 3. Connect the wire connector in front of the subwoofer speaker grill. 4. Connect the wire connector (1). 5. Install the IP extension to the IR. 6. Ensure the proper operation of the subwoofer. Speaker Replacement - Front (Windshield Pillar Speaker) REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console (Tweeter) > Page 12302 1. Remove the windshield garnish molding (2). 2. Disconnect the electrical connector (3) to the speaker. 3. Remove the speaker (1) by press until it is out of the molding. INSTALLATION PROCEDURE 1. Press in the speaker (1) until it is fully seated. 2. Connect the electrical connector (3). 3. Install the windshield garnish molding (2). Speaker Replacement - Front Door REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console (Tweeter) > Page 12303 1. Remove the trim panel. 2. Remove the speaker by pushing down on the top retainer. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the speaker. Push the speaker into place. Ensure that the speaker is completely seated. 3. Install the trim panel. 4. Inspect the component operation. Speaker Replacement - Rear Pillar REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console (Tweeter) > Page 12304 1. Remove the garnish molding. 2. Remove the garnish molding. 3. Remove the speaker. 4. Disconnect the electrical connectors, as necessary. INSTALLATION PROCEDURE 1. Connect the electrical connectors, as necessary. 2. Install the speaker. 3. Install the garnish molding. 4. Install the garnish molding. 5. Verify the component's operation. Speaker Replacement - Rear Door REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console (Tweeter) > Page 12305 1. Remove the door trim panel. 2. Remove the screws (1) retaining the speaker to the mounting bracket. 3. Disconnect the electrical connector from the speaker. 4. Remove the speaker from the mounting bracket. 5. Remove the bolts (2) retaining the speaker mounting bracket to the door, if required. 6. Remove the speaker mounting bracket. INSTALLATION PROCEDURE 1. Install the speaker mounting bracket. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (2) retaining the speaker mounting bracket to the door, if removed. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the speaker to the mounting bracket. 4. Connect the electrical connector to the speaker. 5. Install the screws (1) that retain the speaker to the mounting bracket. Tighten Tighten the screws to 2 N.m (53 lb in). 6. Install the door trim panel. 7. Verify the component operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console (Tweeter) > Page 12306 Speaker Replacement - Rear Quarter (Subwoofer) REMOVAL PROCEDURE 1. Remove the rear quarter trim panel. 2. Remove the bolts which retain the subwoofer assembly to the vehicle. 3. Remove the subwoofer assembly from the vehicle. 4. Disconnect the electrical connectors. 5. Separate the halves of the subwoofer assembly. Disengage the retainers using a flat bladed tool. 6. Remove the speaker from the subwoofer assembly. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console (Tweeter) > Page 12307 1. Install the speaker to the subwoofer assembly. 2. Assemble the halves of the subwoofer assembly. Engage the retainers. 3. Install the subwoofer assembly to the vehicle. 4. Connect the electrical connections. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the bolts which retain the subwoofer assembly to the vehicle. Tighten Tighten the bolts to 9 N.m (80 lb in). 6. Install the rear quarter trim panel. Speaker Replacement - Rear Quarter (Bose Subwoofer) REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console (Tweeter) > Page 12308 1. Remove the rear quarter panel. 2. Remove the rear amplifier, if installed on top of the subwoofer. 3. Remove the subwoofer retaining bolts (1). 4. Disconnect the electrical connector. 5. Remove the subwoofer from the vehicle. INSTALLATION PROCEDURE 1. Install the subwoofer to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the subwoofer retaining bolts (1). Tighten Tighten the bolts to 9.0 N.m (80 lb in). 3. Connect the electrical connector. 4. Install the rear amplifier, if removed from the top of the subwoofer. 5. Install the rear quarter panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Audio System - Clearing `CLN' Message From Display Tape Player: Technical Service Bulletins Audio System - Clearing `CLN' Message From Display File In Section: 08 - Body and Accessories Bulletin No.: 01-08-44-006A Date: June, 2001 INFORMATION Subject: Cleaning the Cassette Tape Player and Clearing the CLN Message from the Radio Display Models: 1996-2002 Chevrolet and GMC Truck Models With Remote Cassette Tape Player (RP0 UP0) This bulletin is being revised to include additional model years and models, parts information, and to provide a procedure for cleaning the cassette tape player and resetting the CLN indicator on the radio display. Please discard Corporate Bulletin Number 01-08-44-006 (Section 08 - Body and Accessories). When the CLN message appears on the audio system, it indicates that the cassette tape player requires cleaning. Customers should follow the listed instructions. The recommended cleaning method for the remote cassette player is to use a scrubbing action, non-abrasive cleaning cassette, GM P/N 12344789. The cleaning cassette scrubs the tape head as the hubs of the cleaner cassette turn. Use the following procedure to clean the remote cassette player and reset the CLN indicator on the radio. 1. With the radio ON, insert the recommended cleaning cassette. 2. After a few seconds, the cleaning cassette may eject because it may appear to the player as a cassette with a broken tape. If ejection occurs, reinsert the cleaning cassette. Continue this process three or four times until the cleaning cassette is engaged for the time recommended by the cleaning cassette instructions. 3. Eject the cleaning cassette if the cassette does not eject on its own. 4. Press and hold the RECALL button on the radio until CLN appears on the radio display. While still pressing the radio RECALL button, press EJECT on the remote player. Release both buttons when the radio display indicates that the CLN indicator timer has been reset. Parts Information Parts are currently available from GMSPO. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Description and Operation > Base Level Tape Player: Description and Operation Base Level 1. In order to play a tape, the ignition switch must be in the ACCESSORY or RUN position and the receiver must be turned ON. Tapes are end-loaded into the cassette player. 2. Insert the tape squarely through the door, exposed tape side of the cassette facing to the right. 3. When the tape is fully inserted, the AM/FM portion of the radio will turn off and the tape will begin playing. 4. The tape player works best with tapes that are 30 - 45 minutes long on each side. Longer running tapes may not work well in these players because they are usually too thin. 5. Once the tape is playing, the volume, balance and fade knobs operate the same as with the radio. An arrow indicates which side of the tape is being played. FWD 1. Press the SEEK right arrow key in order to fast forward the tape. 2. Press the SEEK left arrow key in order to stop the fast forward operation. REV 1. Press the SEEK left arrow key in order to rewind the tape. 2. Press the SEEK right arrow key in order to stop rewinding the tape. RECALL Press the volume control knob to change from one side of the tape to the other. EJECT Press the EJECT push button in order to remove the tape or in order to stop the tape and switch to the radio. CLN 1. If CLN appears on the display, the cassette player needs to be cleaned in order to prevent damage to the tape player. 2. After cleaning the tape player, press and hold the EJECT button for 5 seconds in order to reset the CLN indicator. 3. The radio displays "- - -" in order to show that the indicator has been reset. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Description and Operation > Base Level > Page 12315 Tape Player: Description and Operation Uplevel/Luxury 1. Tapes may be played with the ignition ON or OFF. If the ignition is ON but the radio is OFF, the tape will begin playing. A tape symbol, accompanied by tape direction arrows, is shown in the center of the graphic display whenever a tape is playing. 2. Tapes are end-loaded into these players. Insert the tape squarely through the door, exposed tape side of the cassette facing the right. 3. When the tape is fully inserted, the AM/FM portion of the radio will turn OFF and the tape will begin playing. 4. The tape player works best with tapes that are 30 to 45 minutes long on each side. Longer tapes may not work well in the cassette player because the tapes are so thin. 5. To load a cassette with the ignition in the OFF position, press EJECT or RECALL. 6. Insert the cassette. 7. If the ignition is in the ON position and the radio is in the OFF position, the tape will begin to play. 8. The player automatically senses the tape cartridge for metal or Cr02 tape media and presets the pre-emphasis. For metal tapes, "DD" will be displayed. 9. Any time a tape is playing, use the volume, balance, fade, treble, and bass just as with the radio. An arrow indicates which side of the tape is being played. 10. When you insert a tape, the top of the cassette plays first. PREV ^ Press the PREV or the SEEK left arrow push button in order to search for the previous selection. The tape direction arrow blinks during SEEK operation. ^ A minimum 3 second blank gap is required for proper operation. ^ Audio is muted during SEEK. PROG Press the PROG push button in order to switch from one side of the tape to the other. NEXT ^ Press the NEXT or the SEEK right arrow push button in order to search for the next selection ^ A minimum of a 3 second gap is required for the player to stop at the beginning of a selection. ^ The tape direction arrow will blink during the SEEK operation. REV ^ Press REV in order to rewind the tape. The tape rapidly reverses to the beginning of the cassette or until you press the REV push-button a second time. The radio plays the last selected station during the REV operation. ^ The tape direction arrow blinks during REV operation. DOLBY(R) Dolby Noise Reduction is manufactured under a license from Dolby Laboratories Licensing Corporation. Dolby(R) and the "DD" symbol are trademarks of Dolby Laboratories Licensing Corporation. 1. Press the Dolby push-button in order to reduce cassette tape noise. 2. The "DD" Dolby(R) symbol will appear in the display. FWD 1. Press FWD in order to fast-forward the tape. The tape rapidly advances to the end of the tape or until you press the FWD push-button again. 2. The radio will play the last selected station during the FWD operation. 3. The tape direction arrow blinks during FWD operation. AM-FM Press the AM-FM button in order to switch from tape to radio. TAPE AUX 1. Press TAPE AUX in order to return to the tape player. 2. The lighted arrow appears and shows the direction of play when a tape is in the active mode. EJECT 1. In order to remove the tape, press EJECT. 2. EJECT may be activated with either the ignition or the radio OFF. 3. Cassettes may be loaded with the radio OFF by pressing EJECT before loading the cassette tape. CLN 1. It CLN appears on the display, the cassette player needs to be cleaned in order to prevent damage to the tape player. 2. After cleaning the tape player, press and hold EJECT for 5 seconds in order to reset the CLN indicator. 3. The radio displays "- - - "in order to show that the indicator reset. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12321 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12322 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12323 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12324 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12325 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12326 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12327 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12328 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12329 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12330 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12331 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12332 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12333 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12334 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12335 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12336 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12337 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12338 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12339 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12340 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12341 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12342 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12343 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12344 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12345 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12346 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12347 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12348 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12349 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12350 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 12351 Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) POWER MODE RAP is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its shut-off limit. The body control module monitors the ignition switch position, battery condition and passenger compartment door status to determine whether RAP should be initiated. If the ignition switch transitions from RUN/ON to OFF, the battery level is within the acceptable range and the passenger compartment doors are closed, the body control module closes the RAP relay. This provides power for the following: ^ Sunroof ^ Power windows ^ Power door locks ^ Radio ^ Rear radio ^ OnStar The BCM turns OFF the RAP function and opens the RAP relay when one of the following conditions are met: ^ The BCM senses the opening of any door or the liftgate. ^ The BCM detects a decrease in battery capacity below a prescribed limit. ^ The BCM receives a message from its internal timer indicating the end of the RAP period after 20 minutes. ^ The transition from OFF to RUN/ON or ACC of the ignition switch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Accessory Delay Module Begin the system diagnosis with the Diagnostic System Check Accessory Delay Module. The Diagnostic System Check will provide the following information: ^ The identification of the control module which commands the system ^ The ability of the control module to communicate through the serial data circuit ^ The identification of any stored DTCs and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Accessory Delay Module DIAGNOSTIC SYSTEM CHECK - ACCESSORY DELAY MODULE TEST DESCRIPTION Steps 1-5 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. This step is checking for DTCs in the BCM. 5. This step is checking for RAP specific DTCs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12354 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms - Accessory Delay Module IMPORTANT PRELIMINARY CHECKS BEFORE STARTING 1. Perform the Diagnostic System Check - Retained Accessory Power before using the Symptom Tables in order to verify that all of the following are true: ^ There are no DTCs set. ^ The control module(s) can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check - Accessory Delay Module 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory Power (RAP) Description and Operation. VISUAL/PHYSICAL INSPECTION ^ Inspect for aftermarket devices which could affect the operation of the Retained Accessory Power system. Refer to Checking Aftermarket Accessories in Diagnostic Aids. ^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in Diagnostic Aids. SYMPTOM LIST Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: ^ Retained Accessory Power (RAP) On After Timeout ^ Retained Accessory Power (RAP) Inoperative Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12355 Steps 1-10 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12356 Steps 1-9 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12357 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions MODULE INFORMATION 1 Julian Date of Build: The scan tool displays the date upon which the Body Control Module (BCM) was manufactured. Manufacture Enable Counter (MEC): The scan tool displays the actual value for the MEC in the BCM. This information is for the assembly plant only. Module Part Number: The scan tool displays the part number assigned to the BCM that is currently in the vehicle. Software Design Suffix: The scan tool displays the version of the software part number in the BCM. Software Part Number: The scan tool displays the software identification number (ID) in the BCM. MODULE INFORMATION 2 Retained Accessory Power (RAP) Calibration Number: The scan tool displays the RAP calibration part number in the BCM. Retained Accessory Power (RAP) Suffix: The scan tool displays the RAP identification number in the BCM. DATA Battery Voltage: The scan tool displays the battery system voltage. Inadvertent Power Timer: The scan tool displays the seconds left before the BCM turns the inadvertent power relay OFF. The BCM uses this feature to protect the battery against inadvertent battery rundown caused by components that are part of the courtesy lamp circuit. The inadvertent power relay is supplied power by the BCM for 2400 seconds / 40 minutes after the ignition is turned OFF. RAP Timer: The scan tool displays the seconds left before the BCM turns the RAP relay OFF. The BCM uses this feature to allow the operation of the radio and the power windows for up to 1198 seconds / 20 minutes after the ignition is turned OFF. After the time has elapsed or the door is opened the BCM will open the ground circuit for the RAP relay. INPUT 1 Door Handle Switch: The scan tool displays the position of the door handle. The scan tool displays ACTIVE when a door handle is raised and INACTIVE with all doors closed and the door handles at rest. Drivers Door Jamb Switch: The scan tool displays the position of the drivers door. The scan tool displays ACTIVE when the drivers door is open. Ignition 1: The scan tool displays the position of the ignition switch. The scan tool displays ACTIVE when the ignition switch is in the RUN or CRANK position. Ignition 3: The scan tool displays the position of the ignition switch. The scan tool displays ACTIVE when the ignition switch is in the RUN position only. Ignition Power Mode: The scan tool displays the position of the ignition switch. The scan tool displays OFF, RUN, CRANK and UNKNOWN. The UNKNOWN display is when the BCM can not determine the position of the ignition switch. Key In Ignition: The scan tool displays the position of the ignition key in the ignition switch cylinder. The scan tool displays YES when the ignition key is completely inserted into the ignition switch cylinder. The BCM uses this data in controlling the operation of the reminder chime feature. RAP Relay Feedback: The scan tool displays the state of the RAP relay. The scan tool displays ON when the BCM activates the RAP relay. OUTPUTS RAP Relay: The scan tool displays the commanded state of the RAP relay. The scan tool displays ON when the BCM allows the RAP relay to go to ground. The BCM will allow operation of the radio and the power windows with the ignition OFF and the doors closed for up to 1198 seconds, approximately 20 minutes. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12358 Scan Tool Data List Scan Tool Output Controls Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 12362 Theft Deterrent Control Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 12363 Alarm Module: Service and Repair THEFT DETERRENT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR. Refer to Disabling the SIR System in Restraint Systems. 2. Remove the steering column trim covers. 3. Remove the ignition lock cylinder. 4. Remove the theft deterrent control module wiring harness from the steering column harness. 5. Disconnect the electrical connector from the theft deterrent control module. 6. If, necessary, disconnect the electrical connector from the ignition lock cylinder case. 7. Remove the theft deterrent module (2) away from the lock cylinder housing (1). INSTALLATION PROCEDURE 1. Install the theft deterrent control module (2), onto the lock cylinder housing (1). 2. Install the theft deterrent control module wiring harness to the steering column harness. 3. If, necessary, disconnect the electrical connector from the ignition lock cylinder case. 4. Connect the electrical connector. 5. Install the ignition lock cylinder. 6. Install the steering column trim covers. 7. Enable the SIR system. Refer to Enabling the SIR System in Restraint Systems. 8. Program the new theft deterrent control module. Refer to Programming Theft Deterrent System Components. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Service and Repair Antenna Control Module: Service and Repair RADIO ANTENNA MODULE REPLACEMENT REMOVAL PROCEDURE The Radio control module and the Radio Antenna module cannot be replaced individually. 1. Lower the rear of the headliner. Refer to Headliner Replacement in Interior Trim. 2. Disconnect the wire harness (2) attached to the rear quarter glass panel. 3. Remove the module (3) retaining bolt. 4. Disconnect the antenna cable from the module. 5. Remove the antenna module from the roof. 6. Remove the radio control module. INSTALLATION PROCEDURE 1. Install the radio control module. 2. Install the antenna module to the roof. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the module retaining bolt. Tighten Tighten the retaining bolt to 9 N.m (80 lb in). 4. Connect the antenna cable to the module (3). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Service and Repair > Page 12367 5. Connect the wire harness (2) to the rear quarter glass panel. 6. Install the rear of the headliner. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12376 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12377 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12378 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12379 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12380 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12381 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12382 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12383 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12384 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12385 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12386 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12387 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12388 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12389 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12390 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12391 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12392 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12393 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12394 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12395 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12396 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12397 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12398 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12399 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12400 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12401 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12402 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12403 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12404 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12405 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12406 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12407 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12408 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12409 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 12415 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 12420 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 12425 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 12426 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 12432 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12441 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12442 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12443 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12444 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12445 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12446 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12447 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12448 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12449 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12450 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12451 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12452 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12453 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12454 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12455 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12456 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12457 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12458 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12459 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12460 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12461 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12462 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12463 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12464 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12465 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12466 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12467 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12468 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12469 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12470 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12471 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12472 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12473 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12474 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-64-007A > Sep > 08 > OnStar(R) - Analog Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 12491 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 12496 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 12497 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-007 > Dec > 06 > OnStar - Analog-Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 12507 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12517 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12518 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12519 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12520 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12521 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12522 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12523 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12524 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12525 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12526 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12527 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12528 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12529 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12530 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12531 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12532 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12533 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12534 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12535 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12536 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12537 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12538 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12539 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12540 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12541 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12542 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12543 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12544 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12545 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12546 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12547 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12548 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12549 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12550 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-64-007A > Sep > 08 > OnStar(R) - Analog Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-007 > Dec > 06 > OnStar - Analog-Only Systems Information Emergency Contact Module: All Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Service Manual Revised OnStar(R) VIU & VCU Replacement Global Positioning System Module: Technical Service Bulletins Service Manual - Revised OnStar(R) VIU & VCU Replacement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-46-011 Date: September, 2002 SERVICE MANUAL UPDATE Subject: Revised OnStar(R) Vehicle Interface Unit (VIU) Replacement and OnStar(R) Vehicle Communication Unit (VCU) Replacement Reconfiguration Procedure Models: 2001-2002 Buick LeSabre, Park Avenue 2002 Buick Rendezvous 2001 Cadillac Catera, DeVille, Seville 2001-2002 Cadillac Eldorado 2001 Chevrolet Blazer, Impala, Monte Carlo 2001-2002 Chevrolet Silverado, Suburban, Tahoe, Venture 2001 GMC Envoy, Jimmy 2001-2002 GMC Sierra, Yukon, Yukon XL 2001 Oldsmobile Bravada, Intrigue 2001-2002 Oldsmobile Aurora, Silhouette 2001-2002 Pontiac Aztek, Bonneville, Grand Prix, Montana with Generation 3 OnStar(R) (RPO UE1) This bulletin is being issued to revise the reconfiguration procedure found in the OnStar(R) Vehicle Interface Unit (VIU) Replacement and the OnStar(R) Vehicle Communication Unit (VCU) Replacement procedures in the Cellular Communication sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Due to a new process for configuring replacement Generation 3 (formerly 2.6) OnStar(R) modules for the OnStar(R) Personal Calling feature, vehicles equipped with this version of the system will require a revised OnStar(R) Reconfiguration procedure in the event of module replacement. In addition, the Station Identification Number (STID) and Electronic Serial Number (ESN) numbers are currently accessible by means of the scan tool The procedures for both the Vehicle Interface Unit and Vehicle Communication Unit differ only in which number (STID or ESN) is recorded and transferred to the OnStar(R) Call Center. Important: After replacing the VIU or VCU, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. 1. Press and hold the white Dot button until the OnStar(R) status LED turns from green to red, and back again to green. 2. Install a scan tool. Use the ID information menu to access the new STID (VIU) or ESN (VCU) number. 3. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 4. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center. Tell the advisor that this vehicle has received a new VIU or VCU and ask the advisor to perform the following procedure: 5. Add the new STID (VIU) or ESN (VCU) to update the customer's account. 6. Follow any additional instructions from the OnStar(R) advisor. 7. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Service Manual Revised OnStar(R) VIU & VCU Replacement > Page 12571 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Service Manual - Revised OnStar(R) VIU & VCU Replacement Navigation Module: Technical Service Bulletins Service Manual - Revised OnStar(R) VIU & VCU Replacement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-46-011 Date: September, 2002 SERVICE MANUAL UPDATE Subject: Revised OnStar(R) Vehicle Interface Unit (VIU) Replacement and OnStar(R) Vehicle Communication Unit (VCU) Replacement Reconfiguration Procedure Models: 2001-2002 Buick LeSabre, Park Avenue 2002 Buick Rendezvous 2001 Cadillac Catera, DeVille, Seville 2001-2002 Cadillac Eldorado 2001 Chevrolet Blazer, Impala, Monte Carlo 2001-2002 Chevrolet Silverado, Suburban, Tahoe, Venture 2001 GMC Envoy, Jimmy 2001-2002 GMC Sierra, Yukon, Yukon XL 2001 Oldsmobile Bravada, Intrigue 2001-2002 Oldsmobile Aurora, Silhouette 2001-2002 Pontiac Aztek, Bonneville, Grand Prix, Montana with Generation 3 OnStar(R) (RPO UE1) This bulletin is being issued to revise the reconfiguration procedure found in the OnStar(R) Vehicle Interface Unit (VIU) Replacement and the OnStar(R) Vehicle Communication Unit (VCU) Replacement procedures in the Cellular Communication sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Due to a new process for configuring replacement Generation 3 (formerly 2.6) OnStar(R) modules for the OnStar(R) Personal Calling feature, vehicles equipped with this version of the system will require a revised OnStar(R) Reconfiguration procedure in the event of module replacement. In addition, the Station Identification Number (STID) and Electronic Serial Number (ESN) numbers are currently accessible by means of the scan tool The procedures for both the Vehicle Interface Unit and Vehicle Communication Unit differ only in which number (STID or ESN) is recorded and transferred to the OnStar(R) Call Center. Important: After replacing the VIU or VCU, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. 1. Press and hold the white Dot button until the OnStar(R) status LED turns from green to red, and back again to green. 2. Install a scan tool. Use the ID information menu to access the new STID (VIU) or ESN (VCU) number. 3. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 4. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center. Tell the advisor that this vehicle has received a new VIU or VCU and ask the advisor to perform the following procedure: 5. Add the new STID (VIU) or ESN (VCU) to update the customer's account. 6. Follow any additional instructions from the OnStar(R) advisor. 7. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Service Manual - Revised OnStar(R) VIU & VCU Replacement > Page 12576 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams Parking Assist Control Module: Diagrams Rear Object Sensor Control Module Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 12580 Rear Object Sensor Control Module Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 12581 Parking Assist Control Module: Service and Repair REMOVAL PROCEDURE 1. Lift the right rear seating surface up to gain access to the rear parking aid module. 2. Disconnect the electrical connector from the module. 3. Remove the module retainer. 4. Remove the module from the seat frame. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the module to the seat frame. Tighten Tighten the module retainer to 1.7 N.m (15 lb in). 2. Connect the electrical connector. 3. Lower the seating surface. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12590 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12591 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12592 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12598 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12599 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12600 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12609 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12610 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12611 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 12617 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 12618 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 12619 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams Passlock Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams Parking Assist Distance Sensor: Diagrams Object Sensor - LR Corner Object Sensor - RR Corner Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 12627 Object Sensor - LR Middle Object Sensor - RR Middle Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 12628 Parking Assist Distance Sensor: Service and Repair REAR OBJECT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connectors to the rear object sensor. 2. Lift the locking tabs on the housing (4) and remove the rear object sensor (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 12629 3. Insert a small size screw driver at (3) to release the tabs in order to remove the spring (1). 4. From the inside of the housing push in the tabs and remove. 5. Remove the bezel by pushing it through the fascia. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 12630 IMPORTANT: Do not paint the sensor. 1. Paint the sensor bezel to match the color of the bumper fascia. 2. Align the keyhole (2) with the key (1) and press the sensor bezel into the fascia. 3. Install the housing to the bezel through the back side of the fascia. The housing snaps into the cutouts on the bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 12631 IMPORTANT: The spring keys must be on the top and bottom of the housing. 4. Install the spring (1) to the housing (2) until fully seated. Ensure the sensor is held to the bumper fascia firmly. 5. Install the decoupling ring (2) to the sensor (1). 6. Insert the sensor into the housing (4) with the connector pointing toward the passenger side of the fascia. The sensor tabs snap into the cutouts on the housing (4). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 12632 7. Connect the electrical connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations > Page 12636 Rear Parking Assist (RPA) Disable Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations > Page 12637 Parking Assist Switch: Service and Repair REAR OBJECT ALARM MODULE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the dash trim bezel. 2. Grasp the buttons assembly (2) housing and pull outwards. 3. Disconnect the electrical connector from the rear object alarm module switch. 4. Remove the switch (1) from the housing (2). INSTALLATION PROCEDURE 1. Install the rear object alarm switch into the housing (2). 2. Connect the electrical connector to the switch (1). 3. Install the switch housing into the dash. 4. Install the dash trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions Steering Mounted Controls Transmitter: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12647 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12648 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12649 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12650 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12651 Steering Mounted Controls Transmitter: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12652 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12653 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12654 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12655 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12656 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12657 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12658 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12659 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12660 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12661 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12662 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12663 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12664 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12665 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12666 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12667 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12668 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12669 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12670 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12671 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12672 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12673 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12674 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12675 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12676 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12677 Steering Wheel Controls Schematics: Steering Wheel Controls Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 12678 Steering Mounted Controls Transmitter: Description and Operation STEERING WHEEL CONTROLS (SWC) PROG Press this button to play a station you have programmed on the radio preset buttons on the selected band. If a cassette tape is playing, press this button to play the other side of the tape. If a compact disc is playing in the console-mounted CD changer, press this button to go to the next available CD. SEEK Press the up arrow to tune to the next radio station and the down arrow to tune to the previous radio station. If a cassette tape or compact disc is playing, the player will advance forward with the up arrow to the next track or backward with the down arrow to the previous track. MUTE Press this button to silence the system. Press it again to turn on the sound. VOL Press the up or down arrow to increase or decrease volume. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 12679 Steering Mounted Controls Transmitter: Testing and Inspection Steps 1-7 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 12680 Steps 8-10 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Customer Interest for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Adapter Kit: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Customer Interest for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 12690 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Customer Interest for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 12691 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Adapter Kit: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 12697 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 12698 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams Trailer Connector - Heavy Duty Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Replacement Removal Procedure 1. Disconnect the trailer wiring harness. 2. Remove the hitch platform bolts from the frame rails and the rear bumper. 3. Remove the hitch platform from the vehicle. Installation Procedure 1. Position the hitch platform to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the platform hitch bolts to the frame rails and the rear bumper. Tighten the bolts to 125 N.m (92 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 12705 3. Connect the trailer wiring harness. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12710 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12711 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12712 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12713 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12714 Trailer Lamps: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12715 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12716 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12717 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12718 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12719 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12720 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12721 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12722 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12723 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12724 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12725 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12726 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12727 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12728 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12729 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12730 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12731 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12732 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12733 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12734 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12735 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12736 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12737 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12738 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 12739 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 12748 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 12749 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 12755 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 12756 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams Trailer Connector - Heavy Duty Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12767 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12768 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12769 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12770 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12771 Body Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12772 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12773 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12774 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12775 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12776 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12777 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12778 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12779 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12780 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12781 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12782 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12783 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12784 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12785 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12786 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12787 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12788 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12789 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12790 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12791 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12792 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12793 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12794 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12795 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12796 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12797 Body Control Module: Connector Views Body Control Module Connector (BCM) - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12798 Body Control Module (BCM) - C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12799 Body Control Module (BCM) - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12800 Body Control Module: Electrical Diagrams Controlled/Monitored Subsystem References Controlled/Monitored Subsystem References Body Control Module Schematics: Controlled/Monitored Subsystem References Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12801 Exterior Lighting Systems References Exterior Lighting Systems References Body Control Module Schematics: Exterior Lighting Systems References Interior Lighting Systems References Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12802 Interior Lighting Systems References Body Control Module Schematics: Interior Lighting Systems References Power, Ground and Serial Data Power, Ground and Serial Data Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12803 Body Control Module Schematics: Power, Ground And Serial Data Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures IMPORTANT: If any module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not properly configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: ^ The battery is fully charged. ^ The ignition switch is in the RUN position. ^ The DLC is accessible. ^ All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: ^ Inspect all BCM connections. ^ Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to the Theft Deterrent sub-system for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve History DTCs from all modules. 5. Clear all history DTCs. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 12806 Body Control Module: Removal and Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable(s). 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the BCM from the sliding bracket. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 12807 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. 4. Install the knee bolster. 5. Connect the negative battery cable(s). 6. Reprogram the BCM. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service Bulletins > Recalls for Auxiliary Step / Running Board: > NHTSA03V094000 > Mar > 03 > Recall 03V094000: Running Board Wiring Defect Auxiliary Step / Running Board: Recalls Recall 03V094000: Running Board Wiring Defect DEFECT: Some sport utility vehicle, pickup truck, and minivan conversions equipped with running boards manufactured by Southern Comfort, which include courtesy lights manufactured by American Technology Components, Inc., might overheat when the wire harness is exposed to excessive moisture and road salt. This overheating condition can cause the running board to melt or cause a fire. REMEDY: Dealers will replace the wiring harness on these running boards. The manufacturer has reported that owner notification began March 7, 2003. Owners may contact Southern Comfort at 1800-745-6096. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service Bulletins > By Symptom for Auxiliary Step / Running Board: > NHTSA03V094000 > Mar > 03 > Recall 03V094000: Running Board Wiring Defect Auxiliary Step / Running Board: By Symptom Recall 03V094000: Running Board Wiring Defect DEFECT: Some sport utility vehicle, pickup truck, and minivan conversions equipped with running boards manufactured by Southern Comfort, which include courtesy lights manufactured by American Technology Components, Inc., might overheat when the wire harness is exposed to excessive moisture and road salt. This overheating condition can cause the running board to melt or cause a fire. REMEDY: Dealers will replace the wiring harness on these running boards. The manufacturer has reported that owner notification began March 7, 2003. Owners may contact Southern Comfort at 1800-745-6096. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Step / Running Board: > NHTSA03V094000 > Mar > 03 > Recall 03V094000: Running Board Wiring Defect Auxiliary Step / Running Board: All Technical Service Bulletins Recall 03V094000: Running Board Wiring Defect DEFECT: Some sport utility vehicle, pickup truck, and minivan conversions equipped with running boards manufactured by Southern Comfort, which include courtesy lights manufactured by American Technology Components, Inc., might overheat when the wire harness is exposed to excessive moisture and road salt. This overheating condition can cause the running board to melt or cause a fire. REMEDY: Dealers will replace the wiring harness on these running boards. The manufacturer has reported that owner notification began March 7, 2003. Owners may contact Southern Comfort at 1800-745-6096. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service Bulletins > Page 12826 Auxiliary Step / Running Board: Description and Operation Running Board Description The running boards are a dealer installed option that are mounted on factory installed brackets. The brackets are located under the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Replacement (Z-71) Auxiliary Step / Running Board: Service and Repair Assist Step Replacement (Z-71) Assist Step Replacement (Z-71) Removal Procedure 1. With the aid of a helper, remove the retaining nuts and the spacers (1) from the bottom side of the assist step, and remove the assist step from the vehicle. 2. Remove the rocker panel molding. 3. Drill out the rivets (1) from the assist step brackets. 4. Remove the 5 stud plates (1) from the 5 assist step brackets (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Replacement (Z-71) > Page 12829 5. Remove the 5 retaining bolts (1) from the inner side of the rocker panel. 6. Remove the 5 retaining bolts (2) from the inner side of the rocker panel. 7. Remove the assist step brackets (5) from the vehicle. 8. Drill out the rivets (3) for the rocker panel molding bracket (4). 9. Remove the bracket (4) from the vehicle. Installation Procedure 1. Install the rocker panel molding bracket (4) to the vehicle. 2. Install the rivets (3) that secure the rocker panel molding bracket (4) to the vehicle. 3. Install the assist step brackets (5) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 5 retaining bolts (1) to the inner side of the rocker panel. Tighten the bolts (1) to 29 N.m (21 lb ft). 5. Install the 5 retaining bolts (2) to the inner side of the rocker panel. Tighten the bolts (1) to 10 N.m (89 lb in). 6. Install the 5 stud plates (1) to the 5 assist step brackets (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Replacement (Z-71) > Page 12830 7. Install the rivets (1) that secure the assist step brackets to the rocker panel. 8. Install the rocker panel molding. 9. With the aid of an assistant, install the assist step to the vehicle. 10. Install the spacers and the nuts (1). Tighten the bolts (1) to 29 N.m (21 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Replacement (Z-71) > Page 12831 Auxiliary Step / Running Board: Service and Repair Running Board Replacement (Utility) Running Board Replacement (Utility) Removal Procedure 1. Remove the bolts that attach the running board end caps to the body. 2. Remove the bolts that secure the running board to the brackets. 3. Remove the running boards from the vehicle. 4. Loosen the bolts retaining the HVAC pipes in order to facilitate the removal the assist step brackets. Refer to Heater Pipe Replacement - Auxiliary. 5. Remove the bolts attaching the brackets to the vehicle. 6. Remove the brackets. Installation Procedure 1. Install the brackets to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that secure the brackets to the vehicle. Tighten the bolts to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Replacement (Z-71) > Page 12832 3. Install the running board assembly to the vehicle. 4. Install the bolts that secure the running boards to the brackets. Tighten the bolts to 25 N.m (18 lb ft). 5. Install the bolts retaining the HVAC pipes in order to facilitate the installation of the assist step brackets. Tighten the bracket bolts to 25 N.m (18 lb ft). 6. Install the bolts that secure the end caps to the vehicle. Tighten the bolts to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Bracket > System Information > Service and Repair Front Bumper Bracket: Service and Repair Front Bumper Impact Bar Bracket Replacement (Light Duty) Removal Procedure 1. Remove all related panels and components. IMPORTANT: Do not remove any material from the frame rail when removing the bumper bracket. 2. Remove the damaged bumper bracket. Installation Procedure IMPORTANT: Drill 2 holes on each side of the rail. 1. Position the template as shown. Drill two 15 mm (9/16 in) holes on each side of the frame rail at the locations indicated on the template. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Bracket > System Information > Service and Repair > Page 12838 2. Apply approved anti-corrosion primer to the bare metal surfaces. 3. Insert the sleeve (1) into the rail end as shown. Align the sleeve with the holes drilled in the previous step. IMPORTANT: The bolt plate must be inserted from the outboard side of the rail toward the inboard side. 4. Install the replacement bumper bracket with the supplied bolt plate (1). 5. Hand tighten the fasteners. 6. Install all related panels and components. 7. Align the front bumper assembly. NOTE: Refer to Fastener Note in Service Precautions. 8. Tighten the bolts. Tighten Tighten the bolts to 160 N.m (118 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Air Deflector Replacement - Front Bumper Fascia Front Bumper Cover / Fascia: Service and Repair Air Deflector Replacement - Front Bumper Fascia Air Deflector Replacement - Front Bumper Fascia Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the fog lamp electrical connectors, if equipped. 3. Remove the fog lamps, if equipped. 4. Loosen the center studs of the push-pins on the air deflector with a flat-bladed screwdriver. 5. Remove the air deflector from the front bumper fascia. Chevrolet is shown, GMC is similar. Installation Procedure 1. Position the air deflector onto the front bumper assembly. Chevrolet is shown, GMC is similar. 2. Fasten the connection ends of the push-pins onto the front bumper deflector. 3. Install the fog lamps, if equipped. 4. Connect the fog lamp electrical connectors, if equipped. 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Air Deflector Replacement - Front Bumper Fascia > Page 12845 Front Bumper Cover / Fascia: Service and Repair Fascia Replacement - Front Bumper (Avalanche) Fascia Replacement - Front Bumper (Avalanche) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the brace bolt. 3. Remove the retainers (2) from the fascia (1). 4. Remove the daytime running and fog lamps. 5. Release the front fascia locking fittings from the radiator grille support. 6. Pull the front fascia in order to release the front fascia from the front fender outer panel clips (1). Installation Procedure 1. Install the daytime running and fog lamps. 2. Align the front fascia clips (1) to the front fender outer panel clip retainers. 3. Push the fascia firmly in order to secure the fascia to the radiator grille support and front fender outer panel. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Air Deflector Replacement - Front Bumper Fascia > Page 12846 4. Install the retainers (2) to the fascia (1). Tighten the retainers to 1.6 N.m (14.0 lb in) 5. Install the bolt to the front fascia brace. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Front Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Page 12851 Front Bumper Reinforcement: Service and Repair Brace Replacement - Front Bumper (Avalanche) Removal Procedure 1. Remove the brace bolt (2) from the front bumper fascia. 2. Remove the brace bolt (3) from the outboard mounting brace plate. 3. Remove the brace (1) from the vehicle. Installation Procedure 1. Install the brace (1) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 2 bolts that retain the brace to the fascia and the outboard brace plate. * Tighten the front bumper fascia brace bolt (2) to 15 N.m (11 lb ft). * Tighten the front bumper outboard brace plate bolt (3) to 9 N.m (80 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Customer Interest: > 03-08-43-002A > Sep > 04 > Wipers/Washers - Rear Window Spray Nozzle Dripping Rear Bumper Cover / Fascia: Customer Interest Wipers/Washers - Rear Window Spray Nozzle Dripping File In Section: 08 - Body and Accessories Bulletin No.: 03-08-43-002A Date: September, 2004 TECHNICAL Subject: Rear Window Washer Spray Nozzle Drips Leaving Stain On Rear Bumper Step Cover (Install Additional Rear Window Washer Check Valve and Apply Conditioner to Rear Bumper Cover) Models: 2002-2004 Cadillac Escalade 2003-2004 Cadillac Escalade ESV 2000-2004 Chevrolet Suburban, Tahoe 2000-2004 GMC Yukon, Yukon XL This bulletin is being revised to update the repair procedure and add warranty information. Please discard Corporate Bulletin Number 03-08-43-002 (Section 08 - Body and Accessories). Condition Some customers may comment on the rear window washer spray nozzle dripping and leaving a stain on the rear bumper step cover. Cause The location of the existing rear window washer check valve along with thermal expansion of the valve may be the cause of this condition. Correction Follow the service procedure below to add an additional check valve to the rear window washer hose where it passes through the lift gate sheet metal. 1. Remove the lift gate garnish molding. 1.1. Open the lift gate window. 1.2. Remove the pushpin retainers from the garnish molding. 1.3. Pry gently with a thin-bladed tool in order to release the retaining clips. 1.4. Remove the garnish molding. 2. Remove the lift gate trim panel. 2.1. Remove the pull strap. 2.2. Pry gently with a thin-bladed tool in order to release the retaining clips. 2.3. Slide the trim panel upward to disengage the mounting hooks. 2.4. Remove the trim panel from the lift gate. 3. Locate and remove the straight connector that connects the washer hose to the pass through grommet on the lift gate sheet metal. Discard the straight connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Customer Interest: > 03-08-43-002A > Sep > 04 > Wipers/Washers - Rear Window Spray Nozzle Dripping > Page 12861 4. Install the new washer check valve (1), P/N 22102237, in place of the straight connector. Install with the arrow pointing in the direction of fluid flow. 5. Install the lift gate trim panel. 5.1. Position the trim panel to the lift gate. 5.2. Slide the trim panel downward to engage the mounting hooks. 5.3. Press on the trim panel in order to engage the retaining clips. 5.4. Install the pull strap. 6. Install the lift gate garnish molding. 6.1. Install the molding to the lift gate. 6.2. Press on the molding in order to engage the retaining clips. 6.3. Install the pushpin retainers into the garnish molding. 6.4. Close the lift gate window. Caution: This product should be used in a well ventilated area using nitrile gloves and proper eye protection. This product is flammable, do not use around open flames. These reconditioning wipes may spontaneously combust, be aware of the risk. All personnel should read the Material Safety Data Sheet before using this product. Proper disposal of used wipes should be followed. Important: Make certain that the surface is clean and dry before applying Armor-Dillo. This product will not bond to wet surfaces and, if the surface is not clean, the results will not meet expectations. 7. Apply Armor-Dillo following the procedure below. 7.1 Wash the vehicle with a general purpose cleaner to make certain the surface is clean. 7.2. For ease of clean-up, tape off the painted or chrome bumper surface around step cover and remove the license plate if necessary. 7.3. Apply Armor-Dillo evenly over the surface. 7.4. Allow the product to remain on the surface for a few minutes. Important: If this step is not performed, this product will remain tacky and will attract dirt. 7.5. Use a damp lint free towel and wipe the treated surface thoroughly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Customer Interest: > 03-08-43-002A > Sep > 04 > Wipers/Washers - Rear Window Spray Nozzle Dripping > Page 12862 7.6. A second coat may be needed on severely stained surface and can be applied after Step # 4. Parts Information Warranty Information Important: Please advise the customer that this is a one-time warranty repair and that future coatings are the responsibility of the owner. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > By Symptom: > 03-08-43-002A > Sep > 04 > Wipers/Washers - Rear Window Spray Nozzle Dripping Rear Bumper Cover / Fascia: By Symptom Wipers/Washers - Rear Window Spray Nozzle Dripping File In Section: 08 - Body and Accessories Bulletin No.: 03-08-43-002A Date: September, 2004 TECHNICAL Subject: Rear Window Washer Spray Nozzle Drips Leaving Stain On Rear Bumper Step Cover (Install Additional Rear Window Washer Check Valve and Apply Conditioner to Rear Bumper Cover) Models: 2002-2004 Cadillac Escalade 2003-2004 Cadillac Escalade ESV 2000-2004 Chevrolet Suburban, Tahoe 2000-2004 GMC Yukon, Yukon XL This bulletin is being revised to update the repair procedure and add warranty information. Please discard Corporate Bulletin Number 03-08-43-002 (Section 08 - Body and Accessories). Condition Some customers may comment on the rear window washer spray nozzle dripping and leaving a stain on the rear bumper step cover. Cause The location of the existing rear window washer check valve along with thermal expansion of the valve may be the cause of this condition. Correction Follow the service procedure below to add an additional check valve to the rear window washer hose where it passes through the lift gate sheet metal. 1. Remove the lift gate garnish molding. 1.1. Open the lift gate window. 1.2. Remove the pushpin retainers from the garnish molding. 1.3. Pry gently with a thin-bladed tool in order to release the retaining clips. 1.4. Remove the garnish molding. 2. Remove the lift gate trim panel. 2.1. Remove the pull strap. 2.2. Pry gently with a thin-bladed tool in order to release the retaining clips. 2.3. Slide the trim panel upward to disengage the mounting hooks. 2.4. Remove the trim panel from the lift gate. 3. Locate and remove the straight connector that connects the washer hose to the pass through grommet on the lift gate sheet metal. Discard the straight connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > By Symptom: > 03-08-43-002A > Sep > 04 > Wipers/Washers - Rear Window Spray Nozzle Dripping > Page 12868 4. Install the new washer check valve (1), P/N 22102237, in place of the straight connector. Install with the arrow pointing in the direction of fluid flow. 5. Install the lift gate trim panel. 5.1. Position the trim panel to the lift gate. 5.2. Slide the trim panel downward to engage the mounting hooks. 5.3. Press on the trim panel in order to engage the retaining clips. 5.4. Install the pull strap. 6. Install the lift gate garnish molding. 6.1. Install the molding to the lift gate. 6.2. Press on the molding in order to engage the retaining clips. 6.3. Install the pushpin retainers into the garnish molding. 6.4. Close the lift gate window. Caution: This product should be used in a well ventilated area using nitrile gloves and proper eye protection. This product is flammable, do not use around open flames. These reconditioning wipes may spontaneously combust, be aware of the risk. All personnel should read the Material Safety Data Sheet before using this product. Proper disposal of used wipes should be followed. Important: Make certain that the surface is clean and dry before applying Armor-Dillo. This product will not bond to wet surfaces and, if the surface is not clean, the results will not meet expectations. 7. Apply Armor-Dillo following the procedure below. 7.1 Wash the vehicle with a general purpose cleaner to make certain the surface is clean. 7.2. For ease of clean-up, tape off the painted or chrome bumper surface around step cover and remove the license plate if necessary. 7.3. Apply Armor-Dillo evenly over the surface. 7.4. Allow the product to remain on the surface for a few minutes. Important: If this step is not performed, this product will remain tacky and will attract dirt. 7.5. Use a damp lint free towel and wipe the treated surface thoroughly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > By Symptom: > 03-08-43-002A > Sep > 04 > Wipers/Washers - Rear Window Spray Nozzle Dripping > Page 12869 7.6. A second coat may be needed on severely stained surface and can be applied after Step # 4. Parts Information Warranty Information Important: Please advise the customer that this is a one-time warranty repair and that future coatings are the responsibility of the owner. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Bumper Cover / Fascia: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Bumper Cover / Fascia: > 03-08-43-002A > Sep > 04 > Wipers/Washers - Rear Window Spray Nozzle Dripping Rear Bumper Cover / Fascia: All Technical Service Bulletins Wipers/Washers - Rear Window Spray Nozzle Dripping File In Section: 08 - Body and Accessories Bulletin No.: 03-08-43-002A Date: September, 2004 TECHNICAL Subject: Rear Window Washer Spray Nozzle Drips Leaving Stain On Rear Bumper Step Cover (Install Additional Rear Window Washer Check Valve and Apply Conditioner to Rear Bumper Cover) Models: 2002-2004 Cadillac Escalade 2003-2004 Cadillac Escalade ESV 2000-2004 Chevrolet Suburban, Tahoe 2000-2004 GMC Yukon, Yukon XL This bulletin is being revised to update the repair procedure and add warranty information. Please discard Corporate Bulletin Number 03-08-43-002 (Section 08 - Body and Accessories). Condition Some customers may comment on the rear window washer spray nozzle dripping and leaving a stain on the rear bumper step cover. Cause The location of the existing rear window washer check valve along with thermal expansion of the valve may be the cause of this condition. Correction Follow the service procedure below to add an additional check valve to the rear window washer hose where it passes through the lift gate sheet metal. 1. Remove the lift gate garnish molding. 1.1. Open the lift gate window. 1.2. Remove the pushpin retainers from the garnish molding. 1.3. Pry gently with a thin-bladed tool in order to release the retaining clips. 1.4. Remove the garnish molding. 2. Remove the lift gate trim panel. 2.1. Remove the pull strap. 2.2. Pry gently with a thin-bladed tool in order to release the retaining clips. 2.3. Slide the trim panel upward to disengage the mounting hooks. 2.4. Remove the trim panel from the lift gate. 3. Locate and remove the straight connector that connects the washer hose to the pass through grommet on the lift gate sheet metal. Discard the straight connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Bumper Cover / Fascia: > 03-08-43-002A > Sep > 04 > Wipers/Washers - Rear Window Spray Nozzle Dripping > Page 12879 4. Install the new washer check valve (1), P/N 22102237, in place of the straight connector. Install with the arrow pointing in the direction of fluid flow. 5. Install the lift gate trim panel. 5.1. Position the trim panel to the lift gate. 5.2. Slide the trim panel downward to engage the mounting hooks. 5.3. Press on the trim panel in order to engage the retaining clips. 5.4. Install the pull strap. 6. Install the lift gate garnish molding. 6.1. Install the molding to the lift gate. 6.2. Press on the molding in order to engage the retaining clips. 6.3. Install the pushpin retainers into the garnish molding. 6.4. Close the lift gate window. Caution: This product should be used in a well ventilated area using nitrile gloves and proper eye protection. This product is flammable, do not use around open flames. These reconditioning wipes may spontaneously combust, be aware of the risk. All personnel should read the Material Safety Data Sheet before using this product. Proper disposal of used wipes should be followed. Important: Make certain that the surface is clean and dry before applying Armor-Dillo. This product will not bond to wet surfaces and, if the surface is not clean, the results will not meet expectations. 7. Apply Armor-Dillo following the procedure below. 7.1 Wash the vehicle with a general purpose cleaner to make certain the surface is clean. 7.2. For ease of clean-up, tape off the painted or chrome bumper surface around step cover and remove the license plate if necessary. 7.3. Apply Armor-Dillo evenly over the surface. 7.4. Allow the product to remain on the surface for a few minutes. Important: If this step is not performed, this product will remain tacky and will attract dirt. 7.5. Use a damp lint free towel and wipe the treated surface thoroughly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Bumper Cover / Fascia: > 03-08-43-002A > Sep > 04 > Wipers/Washers - Rear Window Spray Nozzle Dripping > Page 12880 7.6. A second coat may be needed on severely stained surface and can be applied after Step # 4. Parts Information Warranty Information Important: Please advise the customer that this is a one-time warranty repair and that future coatings are the responsibility of the owner. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Bumper Cover / Fascia: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Fascia Replacement - Rear Bumper (Utility) Rear Bumper Cover / Fascia: Service and Repair Fascia Replacement - Rear Bumper (Utility) Fascia Replacement - Rear Bumper (Utility) Removal Procedure 1. Remove the top fascia retainers. 2. Disconnect the license plate lamp harness. 3. Raise and support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 4. Remove the Spare Tire Wheel Hoist Guide Retaining Clips. 5. Remove the push-pin retainers from the underside of the fascia. 6. Remove the fascia from the impact bar. Installation Procedure 1. Align the locator pin of the fascia to the hole in the impact bar. 2. Press the push-pin retainers into the underside of the fascia. 3. Install the Spare Tire Wheel Hoist Guide Retaining Clips. 4. Remove the safety stands, and lower the vehicle. 5. Connect the license plate lamp harness. 6. Install the top fascia retainers. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Fascia Replacement - Rear Bumper (Utility) > Page 12893 Rear Bumper Cover / Fascia: Service and Repair Fascia Replacement - Rear Bumper (Avalanche) Fascia Replacement - Rear Bumper (Avalanche) Removal Procedure 1. Remove the Left/Right Side Step pads. 2. Remove the Left/Right Side Step pads. 3. Remove the Center Step Pad. 4. Remove the Spare Wheel Hoist Guide Shaft from vehicle. 5. Release the retainers from the underside of the fascia. 6. Remove the Fascia from the impact bar. Installation Procedure 1. Install the fascia onto the impact bar. 2. Install the retainers into the underside of the fascia. 3. Install the Spare Wheel Hoist Guide Shaft from vehicle. 4. Install the Center Step Pad. 5. Install the Left/Right Side Step pads. 6. Install the Left/Right Side Step pads. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Rear Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Service and Repair > Pressure Relief Valve Replacement Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement REMOVAL PROCEDURE 1. Open the lift gate. 2. Remove the outer quarter panel upper applique. 3. Remove the upper rear garnish molding. 4. Remove the corner rear garnish molding. 5. Depress the locking tab on the back of the pressure relief valve to remove from the rear of the vehicle. 6. Remove the pressure relief valve from the vehicle. INSTALLATION PROCEDURE 1. Install the pressure relief valve. 2. Press the pressure relief valve to fully seat. 3. Install the upper rear garnish molding. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Service and Repair > Pressure Relief Valve Replacement > Page 12902 4. Install the outer quarter panel upper applique. 5. Close the lift gate Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Service and Repair > Pressure Relief Valve Replacement > Page 12903 Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement (Utility) Pressure Relief Valve Replacement (Utility) Removal Procedure 1. Open the lift gate. 2. Remove the outer quarter panel upper applique. 3. Remove the upper rear garnish molding. 4. Remove the corner rear garnish molding. 5. Depress the locking tab on the back of the pressure relief valve to remove from the rear of the vehicle. 6. Remove the pressure relief valve from the vehicle. Installation Procedure 1. Install the pressure relief valve. 2. Press the pressure relief valve to fully seat. 3. Install the upper rear garnish molding. 4. Install the outer quarter panel upper applique. 5. Close the lift gate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement (Utility) Removal Procedure 1. Open the lift gate. 2. Remove the outer quarter panel upper applique. 3. Remove the upper rear garnish molding. 4. Remove the corner rear garnish molding. 5. Depress the locking tab on the back of the pressure relief valve to remove from the rear of the vehicle. 6. Remove the pressure relief valve from the vehicle. Installation Procedure 1. Install the pressure relief valve. 2. Press the pressure relief valve to fully seat. 3. Install the upper rear garnish molding. 4. Install the outer quarter panel upper applique. 5. Close the lift gate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the wiper arms. 2. Pull up in order to release the outboard air inlet grille panel clips. 3. Remove the attaching clips running along the edges of the center air inlet grille panel. 4. Remove the sheet metal screws on each end of the air inlet grille panel. 5. Disconnect the windshield washer hose from the nozzle underneath the center air inlet grille panel. 6. Remove the air inlet grille panel. Installation Procedure 1. Connect the windshield washer hose to the nozzle under the center air inlet grille panel. 2. Position the air inlet grille panel to the vehicle and attach the clips to the edges of the center air inlet grille panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the sheet metal screws on each end of the air inlet grille panel. Tighten the sheet metal screws to 2 N.m (18 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 12911 4. Align the outboard air inlet grille panel clips and press down in order to install. 5. Install the wiper arms. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Door Stop > Component Information > Service and Repair Door Stop: Service and Repair Bumper Replacement - Rear Door Removal Procedure 1. Remove the bumper bolts. 2. Remove the bumper assembly. Installation Procedure 1. Install the bumper assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bumper bolts. Tighten the bolts to 9 N.m (80 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair Door Handle Replacement - Outside Removal Procedure 1. Remove the trim panel. 2. Remove the water deflector. 3. Remove the outside handle rod from the rod clip. 4. Remove the lock cylinder rod from the rod clip. 5. Remove the outside handle mounting nuts. 6. Remove the rubber cover in order to access the outboard nut. 7. Remove the door-lock cylinder from the outside handle housing. In order to repair a binding lock cylinder, refer to Binding Lock Cylinders. 8. Remove the handle. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 12922 1. Install the handle to the vehicle. 2. If the lock cylinder is replaced, apply lubricant GM P/N 12345120, Canadian P/N 726548, or equivalent, to the inside of the lock case and of the cylinder keyway. 3. Install the door-lock cylinder to the outside handle housing. In order to code a new lock cylinder, refer to Key and Lock Cylinder Coding. 4. Install the lock cylinder clip to the lock cylinder rod. 5. Install the handle rod to the handle assembly clip. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the outside handle mounting nuts. Tighten the nuts to 9 N.m (80 lb in). 7. Install the rubber cover. 8. Install the water deflector. 9. Install the trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Handle Switch > System Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Handle Switch > System Information > Locations > Page 12926 Front Door Handle Switch: Service and Repair REMOVAL PROCEDURE 1. Insert a flat-bladed tool into the slots on the power accessory switch panel in order to release the retainer clips. 2. Remove the switch panel. 3. Disconnect the electrical connectors from the switches. 4. Remove the screws from the switches. 5. Remove the power accessory switches from the switch panel. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the power accessory switches to the switch panel. Tighten Tighten the power accessory switch screws to 2 N.m (18 lb in). 2. Connect the electrical connectors to the switches. 3. Position the switch panel to the door panel. 4. Install the switch panel by pressing the switch panel into place until fully seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement Front Door Interior Handle: Service and Repair Door Handle Replacement Door Handle Replacement - Inside Removal Procedure 1. Remove the trim panel. 2. Remove the mounting bolts from the inside door handle. 3. Slide the inside door handle forward in order to release the unit from the door. 4. Disconnect the control rod from the inside door handle. 5. Remove the door handle assembly from the door. Installation Procedure 1. Connect the control rod to the inside door handle. 2. Slide the handle into place. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the retaining bolts to the inside door handle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement > Page 12931 Tighten the door handle retaining bolts to 9 N.m (80 lb in). 4. Install the trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement > Page 12932 Front Door Interior Handle: Service and Repair Door Handle Components Handle Bezel Replacement - Inside Removal Procedure 1. Insert a flat-bladed tool between the door handle bezel and the trim panel in order to release the handle bezel tab retainers. 2. Remove the door handle bezel from the door panel. Installation Procedure 1. Position the door handle bezel in the door trim panel. 2. Install the door handle bezel to the door panel by pressing the bezel into place until the bezel is completely seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door Front Door Hinge: Service and Repair Door Hinge Pin and Bushing Replacement - Front Door Door Hinge Pin and Bushing Replacement - Front Door The door hinge pins and bushings are not replaceable. If the hinge pins or bushings are damaged, replace the door hinge as an assembly. Refer to Hinge Replacement - Front Door - Door Side and Hinge Replacement - Front Door - Body Side. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door > Page 12937 Front Door Hinge: Service and Repair Hinge Replacement - Front Door - Body Side Hinge Replacement - Front Door - Body Side Removal Procedure 1. Remove all of the related panels and components. 2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar. 3. Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the pillar. Important: Punch the center of the weld so that as much of the weld as possible is removed during the drilling. 4. Center punch each of the four weld marks on the original hinge. Important: Do not drill into the hinge pillar. 5. Drill through the hinge base only, at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw or equivalent. 6. Remove the hinge. If necessary, use a chisel in order to separate the hinge from the pillar. 7. Remove all of the remaining weld from the pillar surface in order to ensure a flush fit of the service hinge. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door > Page 12938 1. Repair any damage done to the pillar during the drilling or the removal of the hinge. 2. Position the service hinge within the scribe marks on the pillar. 3. Center punch each stud location on the hinge pillar according to the service hinge. 4. Drill a 3 mm (1/8 in) (1) pilot hole at each center punch location. Important: Drill bit must be exact size. 5. Drill an 11.5 mm (29/64 in) hole at the pilot locations for the studs. 6. Clean and prepare all of the bare metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 7. Apply approved anti-corrosion primer. 8. Feed fish wire (1), GM P/N 15017229 or the equivalent, through the hinge, the hinge stud hole and out of the conduit hole in the pillar 9. Install stud (2), GM P/N 15017230, supplied with the service hinge into the wire end. Pull the stud into position. 10. Hold the stud in position with the hinge and remove the fish wire. 11. Draw the stud (4) tight through the pillar. Use the nuts GM P/N 11516746 supplied. 12. Repeat steps 8-11 on the remaining stud locations. 13. Remove each service nut. 14. Apply a full-bodied caulk to the entire hinge mounting surface in order to ensure a proper seal. Notice: Refer to Fastener Notice in Service Precautions. 15. Install the hinge (2) to the pillar (3). Use the supplied nuts (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door > Page 12939 Tighten the hinge nuts (4) to 25 N.m (18 lb ft). 16. Clean and prepare all of the surfaces as necessary for refinishing. 17. Apply the sealers. Refinish the surfaces as necessary. 18. Install and align all of the related panels and the components. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door > Page 12940 Front Door Hinge: Service and Repair Hinge Replacement - Front Door - Door Side Hinge Replacement - Front Door - Door Side Removal Procedure 1. Remove all of the related panels and components. 2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar. 3. Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the door. Important: Punch the center of the weld so that as much of the weld as possible is removed during the drilling. 4. Center punch each of the four weld marks on the original hinge base. Important: Do not drill into the door (1). 5. Drill through the hinge base (2) only, at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw (3) or equivalent. 6. Remove the hinge. If necessary, use a chisel in order to separate the hinge from the door. 7. Remove all of the remaining weld from the door surface in order to ensure a flush fit of the service hinge. Installation Procedure 1. Repair any damage done to the door during the drilling or the removal of the hinge. 2. Clean and prepare the backing plate mounting surfaces in order to ensure a flush fit of the backing plate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door > Page 12941 3. Position the service hinge within the scribe marks on the door. 4. Center punch each hole location on the door according to the service hinge. 5. Drill a 3 mm (1/8 in) pilot hole at each center punch location. Important: Drill bit must be exact size. 6. Drill an 11.5 mm (29/64 in) hole at the pilot locations. 7. Clean and prepare all of the bare metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 8. Apply approved anti-corrosion primer. 9. Apply a full-bodied caulk to the entire hinge mounting surface in order to ensure a proper seal. Notice: Refer to Fastener Notice in Service Precautions. 10. Align the hinge (1) and the backing plate (4) with the holes in the door (2) and install the bolts (3) Tighten the bolts to 25 N.m (18 lb ft). 11. Apply the sealers. 12. Refinish the metal surfaces as necessary. 13. Install and align all of the related panels and the components. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Technical Service Bulletins > Customer Interest for Front Door Limiter: > 01-08-64-015 > Oct > 01 > Side Access Door - Squeak or Scraping Noise Front Door Limiter: Customer Interest Side Access Door - Squeak or Scraping Noise File In Section: 08 - Body and Accessories Bulletin No.: 01-08-64-015 Date: October, 2001 TECHNICAL Subject: Front and Rear Side Access Door Noise (Replace Door Check Link) Models: 1999-2002 Chevrolet and GMC C/K Pickup Models (Silverado and Sierra) 2000-2002 Chevrolet and GMC C/K Utility Models (Avalanche, Suburban, Tahoe, Yukon, Yukon XL, Denali) 2001 GMC C3 Sierra 2002 Cadillac Escalade Condition Some customers may comment on a squeak or scraping type noise while opening the front and rear side access doors. Correction Replace the door check link on affected vehicles. Use the part numbers listed below. Refer to the Doors sub-section in the appropriate Service Manual for the Door Check Link Replacement procedure. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table as shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Limiter: > 01-08-64-015 > Oct > 01 > Side Access Door - Squeak or Scraping Noise Front Door Limiter: All Technical Service Bulletins Side Access Door - Squeak or Scraping Noise File In Section: 08 - Body and Accessories Bulletin No.: 01-08-64-015 Date: October, 2001 TECHNICAL Subject: Front and Rear Side Access Door Noise (Replace Door Check Link) Models: 1999-2002 Chevrolet and GMC C/K Pickup Models (Silverado and Sierra) 2000-2002 Chevrolet and GMC C/K Utility Models (Avalanche, Suburban, Tahoe, Yukon, Yukon XL, Denali) 2001 GMC C3 Sierra 2002 Cadillac Escalade Condition Some customers may comment on a squeak or scraping type noise while opening the front and rear side access doors. Correction Replace the door check link on affected vehicles. Use the part numbers listed below. Refer to the Doors sub-section in the appropriate Service Manual for the Door Check Link Replacement procedure. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table as shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Limiter: > Page 12955 Front Door Limiter: By Symptom Technical Service Bulletin # 01-08-64-015 Date: 011001 Side Access Door - Squeak or Scraping Noise File In Section: 08 - Body and Accessories Bulletin No.: 01-08-64-015 Date: October, 2001 TECHNICAL Subject: Front and Rear Side Access Door Noise (Replace Door Check Link) Models: 1999-2002 Chevrolet and GMC C/K Pickup Models (Silverado and Sierra) 2000-2002 Chevrolet and GMC C/K Utility Models (Avalanche, Suburban, Tahoe, Yukon, Yukon XL, Denali) 2001 GMC C3 Sierra 2002 Cadillac Escalade Condition Some customers may comment on a squeak or scraping type noise while opening the front and rear side access doors. Correction Replace the door check link on affected vehicles. Use the part numbers listed below. Refer to the Doors sub-section in the appropriate Service Manual for the Door Check Link Replacement procedure. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table as shown. DISCLAIMER Technical Service Bulletin # 01-08-64-015 Date: 011001 Side Access Door - Squeak or Scraping Noise File In Section: 08 - Body and Accessories Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Limiter: > Page 12956 Bulletin No.: 01-08-64-015 Date: October, 2001 TECHNICAL Subject: Front and Rear Side Access Door Noise (Replace Door Check Link) Models: 1999-2002 Chevrolet and GMC C/K Pickup Models (Silverado and Sierra) 2000-2002 Chevrolet and GMC C/K Utility Models (Avalanche, Suburban, Tahoe, Yukon, Yukon XL, Denali) 2001 GMC C3 Sierra 2002 Cadillac Escalade Condition Some customers may comment on a squeak or scraping type noise while opening the front and rear side access doors. Correction Replace the door check link on affected vehicles. Use the part numbers listed below. Refer to the Doors sub-section in the appropriate Service Manual for the Door Check Link Replacement procedure. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table as shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Technical Service Bulletins > Page 12957 Front Door Limiter: Service and Repair Door Check Link Replacement Removal Procedure 1. Open the door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the body-side check strap bolt. 5. Remove the check strap plug. 6. Remove the door-side check strap nuts. 7. Pull the check strap from the inside of the door. Installation Procedure 1. Install the check strap to the door. 2. Install the check strap to the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the check strap nuts. Tighten the nuts to 9 N.m (80 lb in). 4. Install the check strap bolt. Tighten the bolt to 25 N.m (18 lb in). 5. Install the water deflector. 6. Install the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest: > 03-08-44-011 > Jun > 03 > Audio System Tweeter Rattles in Front Door(s) Front Door Panel: Customer Interest Audio System - Tweeter Rattles in Front Door(s) Bulletin No.: 03-08-44-011 Date: June 27, 2003 TECHNICAL Subject: Tweeter Speaker Rattle in Front Side Door(s), Tweeter Speaker Falls Out of Position (Modify Door Trim Panel and/or Add Grommets and Replace Tweeter Speaker) Models: 1999-2003 Chevrolet Silverado Pickup Models 2000-2003 Chevrolet Tahoe, Suburban 2002-2003 Chevrolet Avalanche 1999-2003 GMC Sierra Pickup Models 2000-2003 GMC Yukon, Yukon XL with Uplevel Audio System (Non-Bose(R)) (RPO UQ3) Condition Some customers may comment on a rattle noise in either front side door or that the upper tweeter speaker has fallen out of position. Cause A material incompatibility between the door trim and the door tweeter speaker may cause this condition. Over time, the two posts used to attach the tweeter to the door trim may fracture. Correction New grommets have been released that will be placed over the tweeter speaker posts to isolate the two materials and correct this condition. Grommets will have to be attached to the current stock of tweeter part numbers. The new tweeters will have the two grommets already attached to the posts. Replace the tweeter speaker and add grommets as necessary. The door trim panel post holes for any tweeter part number will have to be slightly enlarged to accommodate the grommets. Use the following procedure and refer to the Parts Information for the applicable speaker parts/usage. 1. Remove the front door trim panel. Refer to the Trim Panel Replacement - Side Front Door procedure in the Doors sub-section of SI. 2. Remove the speaker grille. Refer to the Speaker Grille Replacement - Front Door procedure in the Entertainment sub-section of SI. 3. Remove the tweeter speaker retaining nuts. 4. Remove the speaker from the door trim panel. 5. Enlarge the two tweeter speaker mounting holes in the door trim panel to 9.525 mm (0.375 in) (3/8 in). This will accommodate the grommets. This Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest: > 03-08-44-011 > Jun > 03 > Audio System Tweeter Rattles in Front Door(s) > Page 12966 step is required before the installation of any tweeter part number. 6. If replacement tweeter speaker P/N is 15772411 or 15071121, attach one grommet (3), P/N 15204327, to each of the speaker posts. 7. Position the speaker (4) into the opening in the door trim panel (2). 8. Install the tweeter speaker retaining nuts (1). Tighten Tighten to 1.6 N.m (14 lb in). 9. Install the speaker grille. Refer to the Speaker Grille Replacement - Front Door procedure in the Entertainment sub-section of SI. 10. Install the front door trim panel. Refer to the Trim Panel Replacement - Side Front Door procedure in the Doors sub-section of SI. Parts Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest: > 03-08-44-011 > Jun > 03 > Audio System Tweeter Rattles in Front Door(s) > Page 12967 Parts are expected to be available 7-17-2003 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 03-08-44-011 > Jun > 03 > Audio System - Tweeter Rattles in Front Door(s) Front Door Panel: All Technical Service Bulletins Audio System - Tweeter Rattles in Front Door(s) Bulletin No.: 03-08-44-011 Date: June 27, 2003 TECHNICAL Subject: Tweeter Speaker Rattle in Front Side Door(s), Tweeter Speaker Falls Out of Position (Modify Door Trim Panel and/or Add Grommets and Replace Tweeter Speaker) Models: 1999-2003 Chevrolet Silverado Pickup Models 2000-2003 Chevrolet Tahoe, Suburban 2002-2003 Chevrolet Avalanche 1999-2003 GMC Sierra Pickup Models 2000-2003 GMC Yukon, Yukon XL with Uplevel Audio System (Non-Bose(R)) (RPO UQ3) Condition Some customers may comment on a rattle noise in either front side door or that the upper tweeter speaker has fallen out of position. Cause A material incompatibility between the door trim and the door tweeter speaker may cause this condition. Over time, the two posts used to attach the tweeter to the door trim may fracture. Correction New grommets have been released that will be placed over the tweeter speaker posts to isolate the two materials and correct this condition. Grommets will have to be attached to the current stock of tweeter part numbers. The new tweeters will have the two grommets already attached to the posts. Replace the tweeter speaker and add grommets as necessary. The door trim panel post holes for any tweeter part number will have to be slightly enlarged to accommodate the grommets. Use the following procedure and refer to the Parts Information for the applicable speaker parts/usage. 1. Remove the front door trim panel. Refer to the Trim Panel Replacement - Side Front Door procedure in the Doors sub-section of SI. 2. Remove the speaker grille. Refer to the Speaker Grille Replacement - Front Door procedure in the Entertainment sub-section of SI. 3. Remove the tweeter speaker retaining nuts. 4. Remove the speaker from the door trim panel. 5. Enlarge the two tweeter speaker mounting holes in the door trim panel to 9.525 mm (0.375 in) (3/8 in). This will accommodate the grommets. This Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 03-08-44-011 > Jun > 03 > Audio System - Tweeter Rattles in Front Door(s) > Page 12973 step is required before the installation of any tweeter part number. 6. If replacement tweeter speaker P/N is 15772411 or 15071121, attach one grommet (3), P/N 15204327, to each of the speaker posts. 7. Position the speaker (4) into the opening in the door trim panel (2). 8. Install the tweeter speaker retaining nuts (1). Tighten Tighten to 1.6 N.m (14 lb in). 9. Install the speaker grille. Refer to the Speaker Grille Replacement - Front Door procedure in the Entertainment sub-section of SI. 10. Install the front door trim panel. Refer to the Trim Panel Replacement - Side Front Door procedure in the Doors sub-section of SI. Parts Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 03-08-44-011 > Jun > 03 > Audio System - Tweeter Rattles in Front Door(s) > Page 12974 Parts are expected to be available 7-17-2003 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Column Bearing: All Technical Service Bulletins Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 12980 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 12981 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 12982 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures Steering Column Bearing: All Technical Service Bulletins Steering - Revised Service Procedures Bulletin No.: 03-02-36-002 Date: July 30, 2003 SERVICE MANUAL UPDATE Subject: Revised Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Procedure and Steering Wheel Position Sensor Centering Procedure Models: 1998-2003 Buick LeSabre, Park Avenue 1998-2003 Cadillac DeVille, Seville 2003 Cadillac CTS 1998-2003 Chevrolet Corvette 1998 Oldsmobile Achieva 1998-2002 Oldsmobile Intrigue 1998-2003 Oldsmobile Aurora 1999-2003 Oldsmobile Alero 1998-2003 Pontiac Bonneville, Grand Am 1998-2000 Chevrolet C/K Pickup Models 1998-2003 Chevrolet Suburban, Tahoe 1999-2003 Chevrolet Silverado 2002-2003 Chevrolet Avalanche 1998-1999 GMC Suburban 1998-2000 GMC C/K Pickup Models 1998-2003 GMC Yukon 1999-2003 GMC Sierra 2000-2003 GMC Yukon Denali, Yukon XL 2003 GMC Sierra Denali This bulletin is being issued to revise the Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement procedure in the Variable Effort Steering (1998-2001 model years) or Steering Wheel and Column (2002-2003 model years) and add the Steering Wheel Position Sensor Centering procedure in the Steering Wheel and Column sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Removal Procedure Caution: Refer to SIR Caution in Cautions and Notices. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. 2. Remove the steering column from the vehicle. Refer to Steering Column Replacement. 3. Remove the following from the steering shaft: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 12987 3.1. steering shaft seal (7) 3.2. sensor retainer (6) 3.3. steering wheel position sensor (5), refer to Steering Wheel Position Sensor Centering. 3.4. 2 lower spring retainers (4) 3.5. lower bearing spring (3) 3.6. lower bearing seat (2) 3.7. adapter and bearing assembly (1) Installation Procedure 1. Install the following onto the steering shaft: 1.1. adapter and bearing assembly (1) 1.2. lower bearing seat (2) 1.3. lower bearing spring (3) 1.4. 2 lower spring retainers (4) 1.5. steering wheel position sensor (5) refer to Steering Wheel Position Sensor Centering. 1.6. sensor retainer (6) 1.7. steering shaft seal (7) 1.8. Enable the SIR system. Refer to in SIR. 2. Install the steering column to the vehicle. Refer to Steering Column Replacement. 3. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations below BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 12988 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin (note location of the pin hole) ^ A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 12989 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation section. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation section. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 12990 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin (note location of the pin hole) ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation section. 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation section. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 12991 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin (note location of the pin hole) ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly. ^ A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 12992 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats(1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 12993 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin (note location of the pin hole) ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 03-02-36-002 > Jul > 03 > Steering - Revised Service Procedures > Page 12994 Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 12995 Front Door Panel: By Symptom Technical Service Bulletin # 03-08-44-011 Date: 030627 Audio System - Tweeter Rattles in Front Door(s) Bulletin No.: 03-08-44-011 Date: June 27, 2003 TECHNICAL Subject: Tweeter Speaker Rattle in Front Side Door(s), Tweeter Speaker Falls Out of Position (Modify Door Trim Panel and/or Add Grommets and Replace Tweeter Speaker) Models: 1999-2003 Chevrolet Silverado Pickup Models 2000-2003 Chevrolet Tahoe, Suburban 2002-2003 Chevrolet Avalanche 1999-2003 GMC Sierra Pickup Models 2000-2003 GMC Yukon, Yukon XL with Uplevel Audio System (Non-Bose(R)) (RPO UQ3) Condition Some customers may comment on a rattle noise in either front side door or that the upper tweeter speaker has fallen out of position. Cause A material incompatibility between the door trim and the door tweeter speaker may cause this condition. Over time, the two posts used to attach the tweeter to the door trim may fracture. Correction New grommets have been released that will be placed over the tweeter speaker posts to isolate the two materials and correct this condition. Grommets will have to be attached to the current stock of tweeter part numbers. The new tweeters will have the two grommets already attached to the posts. Replace the tweeter speaker and add grommets as necessary. The door trim panel post holes for any tweeter part number will have to be slightly enlarged to accommodate the grommets. Use the following procedure and refer to the Parts Information for the applicable speaker parts/usage. 1. Remove the front door trim panel. Refer to the Trim Panel Replacement - Side Front Door procedure in the Doors sub-section of SI. 2. Remove the speaker grille. Refer to the Speaker Grille Replacement - Front Door procedure in the Entertainment sub-section of SI. 3. Remove the tweeter speaker retaining nuts. 4. Remove the speaker from the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 12996 5. Enlarge the two tweeter speaker mounting holes in the door trim panel to 9.525 mm (0.375 in) (3/8 in). This will accommodate the grommets. This step is required before the installation of any tweeter part number. 6. If replacement tweeter speaker P/N is 15772411 or 15071121, attach one grommet (3), P/N 15204327, to each of the speaker posts. 7. Position the speaker (4) into the opening in the door trim panel (2). 8. Install the tweeter speaker retaining nuts (1). Tighten Tighten to 1.6 N.m (14 lb in). 9. Install the speaker grille. Refer to the Speaker Grille Replacement - Front Door procedure in the Entertainment sub-section of SI. 10. Install the front door trim panel. Refer to the Trim Panel Replacement - Side Front Door procedure in the Doors sub-section of SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 12997 Parts Information Parts are expected to be available 7-17-2003 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 12998 Disclaimer Technical Service Bulletin # 03-08-44-011 Date: 030627 Audio System - Tweeter Rattles in Front Door(s) Bulletin No.: 03-08-44-011 Date: June 27, 2003 TECHNICAL Subject: Tweeter Speaker Rattle in Front Side Door(s), Tweeter Speaker Falls Out of Position (Modify Door Trim Panel and/or Add Grommets and Replace Tweeter Speaker) Models: 1999-2003 Chevrolet Silverado Pickup Models 2000-2003 Chevrolet Tahoe, Suburban 2002-2003 Chevrolet Avalanche 1999-2003 GMC Sierra Pickup Models 2000-2003 GMC Yukon, Yukon XL with Uplevel Audio System (Non-Bose(R)) (RPO UQ3) Condition Some customers may comment on a rattle noise in either front side door or that the upper tweeter speaker has fallen out of position. Cause A material incompatibility between the door trim and the door tweeter speaker may cause this condition. Over time, the two posts used to attach the tweeter to the door trim may fracture. Correction New grommets have been released that will be placed over the tweeter speaker posts to isolate the two materials and correct this condition. Grommets will have to be attached to the current stock of tweeter part numbers. The new tweeters will have the two grommets already attached to the posts. Replace the tweeter speaker and add grommets as necessary. The door trim panel post holes for any tweeter part number will have to be slightly enlarged to accommodate the grommets. Use the following procedure and refer to the Parts Information for the applicable speaker parts/usage. 1. Remove the front door trim panel. Refer to the Trim Panel Replacement - Side Front Door procedure in the Doors sub-section of SI. 2. Remove the speaker grille. Refer to the Speaker Grille Replacement - Front Door procedure in the Entertainment sub-section of SI. 3. Remove the tweeter speaker retaining nuts. 4. Remove the speaker from the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 12999 5. Enlarge the two tweeter speaker mounting holes in the door trim panel to 9.525 mm (0.375 in) (3/8 in). This will accommodate the grommets. This step is required before the installation of any tweeter part number. 6. If replacement tweeter speaker P/N is 15772411 or 15071121, attach one grommet (3), P/N 15204327, to each of the speaker posts. 7. Position the speaker (4) into the opening in the door trim panel (2). 8. Install the tweeter speaker retaining nuts (1). Tighten Tighten to 1.6 N.m (14 lb in). 9. Install the speaker grille. Refer to the Speaker Grille Replacement - Front Door procedure in the Entertainment sub-section of SI. 10. Install the front door trim panel. Refer to the Trim Panel Replacement - Side Front Door procedure in the Doors sub-section of SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 13000 Parts Information Parts are expected to be available 7-17-2003 from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 13001 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Bezel Replacement Front Door Panel: Service and Repair Bezel Replacement Handle Bezel Replacement - Inside Removal Procedure 1. Insert a flat-bladed tool between the door handle bezel and the trim panel in order to release the handle bezel tab retainers. 2. Remove the door handle bezel from the door panel. Installation Procedure 1. Position the door handle bezel in the door trim panel. 2. Install the door handle bezel to the door panel by pressing the bezel into place until the bezel is completely seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Bezel Replacement > Page 13004 Front Door Panel: Service and Repair Panel Replacement Trim Panel Replacement - Side Front Door REMOVAL PROCEDURE 1. Remove the door handle bezel. 2. Remove the window handle, if equipped. 3. Remove the power accessory switch panel. 4. Remove the upper extension of the trim panel. 5. Remove the manual lock lever from the trim panel using a flat bladed tool. 6. Remove the trim panel screws. 7. Remove the courtesy lamp, if equipped. 8. Remove the trim panel from the door. Carefully slide the trim panel up in order to release the retainers from the door. 9. Disconnect the electrical connectors. INSTALLATION PROCEDURE 1. Connect the electrical connectors. 2. Install the courtesy lamp, if equipped. 3. Carefully align the panel, and slide the panel into the retainer slots in order to install the trim panel to the door. 4. Install the window handle, if equipped. 5. Install the power accessory switch panel. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Bezel Replacement > Page 13005 6. Install the trim panel screws. Tighten Tighten the trim panel screws to 2 N.m (18 lb in). 7. Install the manual lock lever to the trim panel. 8. Install the upper extension of the trim panel. 9. Install the door handle bezel. Trim Panel Replacement - Side Front Door (Old) Trim Panel Replacement - Side Front Door (Old) Removal Procedure 1. Remove the door handle bezel. 2. Remove the window handle, if equipped. 3. Remove the power accessory switch panel. 4. Remove the upper extension of the trim panel. 5. Remove the manual lock lever from the trim panel using a flat bladed tool. 6. Remove the trim panel screws. 7. Remove the courtesy lamp, if equipped. 8. Remove the trim panel from the door. Carefully slide the trim panel up in order to release the retainers from the door. 9. Disconnect the electrical connectors. Installation Procedure 1. Connect the electrical connectors. 2. Install the courtesy lamp, if equipped. 3. Carefully align the panel, and slide the panel into the retainer slots in order to install the trim panel to the door. 4. Install the window handle, if equipped. 5. Install the power accessory switch panel. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the trim panel screws. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Bezel Replacement > Page 13006 Tighten the trim panel screws to 2 N.m (18 lb in). 7. Install the manual lock lever to the trim panel. 8. Install the upper extension of the trim panel. 9. Install the door handle bezel. Trim Panel Replacement - Upper Extension REMOVAL PROCEDURE 1. Open the front door. 2. Release the upper extension by pulling outward in order to release the upper retainer clip. 3. Remove the upper extension from the trim panel by lifting up and out. INSTALLATION PROCEDURE 1. Position the lower retainer to the trim panel. 2. Align the upper retainer clip to the door frame. 3. Install the upper extension by pressing into place until fully seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Bezel Replacement > Page 13007 Front Door Panel: Service and Repair Water Deflector Replacement - Front Door Water Deflector Replacement - Front Door Removal Procedure 1. Remove the trim panel. 2. Remove inside door handle. 3. Note location of wiring and remove through deflector. 4. Using a flat-bladed tool, separate the bond between the sealer and the door. 5. Pull the waterproof sealing tape from the deflector. 6. Remove the water deflector. Installation Procedure 1. Using waterproof tape, or 3M(R) 777, or equivalent, install the water deflector to the door. 2. Install the trim panel to the door. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair Front Door Striker: Service and Repair Striker Replacement - Door Removal Procedure Important: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the lower striker bolt. 2. Loosen the upper striker bolt enough in order to rotate the striker and the spacer (if equipped) away from the lower bolt hole. 3. Install the lower striker bolt. Tighten the lower striker bolt sufficiently in order to hold the striker backing plate in place. 4. Remove the upper striker bolt. 5. Remove the spacer, if equipped. 6. Remove the striker. Installation Procedure 1. Install the striker. 2. Install the spacer, if equipped. 3. Install the upper striker bolt. 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. 5. Remove the lower bolt. 6. Rotate the striker and the spacer, (if equipped) in order to align the lower threaded hole in the striker backing plate. Notice: Refer to Fastener Notice in Service Precautions. 7. Tighten the striker bolts. Tighten the door striker bolts to 24 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door (Door Opening) Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door (Door Opening) Weatherstrip Replacement - Front Door (Door Opening) Removal Procedure 1. Open the door. 2. Remove the sill plate. 3. Remove the hinge pillar trim panel. 4. Remove the windshield pillar molding. 5. Remove the weatherstrip from the rear side door opening. Peel the unit away from channel, pulling the weatherstrip from the pinchweld flange. Installation Procedure 1. Install the weatherstrip from the rear side door opening fully seating the weatherstrip into the channel. 2. Install the windshield pillar molding. 3. Install the hinge pillar trim panel. 4. Install the sill plate. 5. Check door closing effort and seal to door fit. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door (Door Opening) > Page 13015 Front Door Weatherstrip: Service and Repair Sealing Strip Replacement - Front Door WDO Belt Outer - Front REMOVAL PROCEDURE IMPORTANT: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outside mirror. 3. Remove the outer sealing strip from the door, lifting up on the forward end in order to unhook the rear of the strip from the window run channel. INSTALLATION PROCEDURE 1. Hook the rear end of the sealing strip into the window run channel. Lower and press the strip into place. 2. Install the outside mirror. 3. Raise the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door (Door Opening) > Page 13016 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Upper Auxiliary Weatherstrip Replacement - Front Door Upper Auxiliary Removal Procedure 1. Open the door. 2. Pull the roof drip molding from the pinch-weld flange and the windshield molding flange. Installation Procedure 1. Push the roof drip molding over the pinch-weld flange. 2. Close the door. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window Front Door Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Window REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the window. 4. Remove the screws. 5. Pull the weatherstrip from the following locations: ^ The front of the glass run channel ^ The top of the window frame flange ^ The rear of the glass run channel 6. Remove the weatherstrip from the door. INSTALLATION PROCEDURE 1. Install the weatherstrip to the following locations: ^ The front of the glass run channel ^ The top of the window frame flange ^ The rear of the glass run channel NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts. Tighten Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 13022 Tighten the bolts to 6 N.m (53 lb in). 3. Install the window. 4. Install the water deflector. 5. Install the door trim panel. 6. Inspect the operation of the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 13023 Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel REMOVAL PROCEDURE 1. Remove the window. 2. Remove the window glass weatherstrip. 3. Remove the window run channel bolts. 4. Remove the front and the rear window run channels from the door INSTALLATION PROCEDURE 1. Install the front and the rear window run channels to the door. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the front and the rear window run channel bolts. Tighten 2.1. Tighten the front bolt to 9 N.m (80 lb in). 2.2. Tighten the rear bolt to 9 N.m (80 lb in). 3. Install the window glass weatherstrip. 4. Install the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 13024 Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Front Door Window Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the window. 4. Remove the screws. 5. Pull the weatherstrip from the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel 6. Remove the weatherstrip from the door. Installation Procedure 1. Install the weatherstrip to the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts. Tighten the bolts to 6 N.m (53 lb in). 3. Install the window. 4. Install the water deflector. 5. Install the door trim panel. 6. Inspect the operation of the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 13025 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Outer - Front Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outside mirror. 3. Remove the outer sealing strip from the door, lifting up on the forward end in order to unhook the rear of the strip from the window run channel. Installation Procedure 1. Hook the rear end of the sealing strip into the window run channel. Lower and press the strip into place. 2. Install the outside mirror. 3. Raise the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair REMOVAL PROCEDURE 1. Raise the window. If the window motor is inoperable, remove the glass window to gain access to the window mote retaining screws. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the door speaker. 5. Support the glass. 6. Disconnect the wiring harness from the window regulator motor. 7. Remove the 3 bolts (1) from the window motor located on the front side of the motor. IMPORTANT: Do not allow the cable gear to come out the housing. Failure will result in the cable coming off the spool. 8. Separate the motor from the cable housing by wiggling the window motor. Observe the orientation of the window motor. 9. Remove the motor from the window regulator assembly. INSTALLATION PROCEDURE 1. Install the window motor to the cable housing by wiggling it into place. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts (1) to the window regulator motor. Tighten Tighten the bolts to 5 N.m (44 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Page 13029 3. Install the glass window, if removed. 4. Connect the wiring harness to the window regulator motor. 5. Remove the window support. 6. Connect the wire connector to the switch to inspect the operation of the window. After inspection disconnect the wire harness and continue the installation. 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Front Door Module Replacement Front Door Window Regulator: Service and Repair Front Door Module Replacement Module Replacement - Front Power Window Removal Procedure 1. Raise and support the window glass. 2. Remove the trim panel. 3. Remove the water deflector. 4. Disconnect the harness from the electric window motor assembly. 5. Remove the 2 bolts that hold the window glass to the regulator. 6. Remove the bolts from the window regulator. 7. Remove the window regulator assembly from the door by folding both sides of the window regulator assembly together. Installation Procedure 1. Install the regulator to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the window regulator. Tighten Tighten the bolts to 9 N.m (80 lb in). 3. Align the window glass to the regulator, and install the bolts that hold the window glass to the regulator. Tighten Tighten the bolts to 9 N.m (80 lb in). 4. Connect the harness to the electric window motor assembly. 5. Install the water deflector. 6. Install the trim panel. 7. Lower the window. Inspect the operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Front Door Module Replacement > Page 13034 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Motor Replacement Window Regulator Motor Replacement - Front Door Removal Procedure 1. Raise the window. If the window motor is inoperable, remove the glass window to gain access to the window motor retaining screws. Refer to Window Replacement - Front Door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the door speaker. 5. Support the glass. 6. Disconnect the wiring harness from the window regulator motor. 7. Remove the 3 bolts (1) from the window motor located on the front side of the motor. Important: Do not allow the cable gear to come out of the housing. Failure will result in the cable coming off the spool. 8. Separate the motor from the cable housing by wiggling the window motor. Observe the orientation of the window motor. 9. Remove the motor from the window regulator assembly. Installation Procedure 1. Install the window motor to the cable housing by wiggling it into place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts (1) to the window regulator motor. Tighten Tighten the bolts to 5 N.m (44 lb in). 3. Install the glass window, if removed. 4. Connect the wiring harness to the window regulator motor. 5. Remove the window support. 6. Connect the wire connector to the switch to inspect the operation of the window. After inspection disconnect the wire harness and continue the installation. 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Door Handle Replacement Rear Door Exterior Handle: Service and Repair Door Handle Replacement Lock Rod and Outside Handle Replace - Rear Door Removal Procedure 1. Remove the trim panel, as necessary. 2. Pull back the water deflector, as necessary. Refer to Water Deflector Replacement. 3. Disconnect the lock cylinder rod from the rod clip. 4. Remove the outside handle nuts. 5. Remove the outside handle. 6. Disconnect electrical connector if required. 7. Remove actuator cable. 8. Remove the door lock cylinder. 9. Complete the necessary procedures: * For repair of a binding lock cylinder, refer to Binding Lock Cylinders. * For coding a new lock cylinder, refer to Key and Lock Cylinder Coding. Installation Procedure Important: When installing a new lock cylinder, apply GM P/N 12345120, or Canadian P/N 726548, lubricant or a similar lubricant to the inside of the lock case and the cylinder keyway. 1. Install the door lock cylinder. 2. Install the actuator cable. 3. Connect the electrical connector if required. 4. Install the handle assembly. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the outside handle mounting nuts. Tighten the nuts to 9 N.m (80 lb in). 6. Connect the lock cylinder rod to the rod clip. 7. Install the water deflector, as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Door Handle Replacement > Page 13041 8. Install the trim panel, as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Door Handle Replacement > Page 13042 Rear Door Exterior Handle: Service and Repair Door Handle Components Lock Rod and Outside Handle Replace - Rear Door Removal Procedure 1. Remove the trim panel, as necessary. 2. Pull back the water deflector, as necessary. Refer to Water Deflector Replacement. 3. Disconnect the lock cylinder rod from the rod clip. 4. Remove the outside handle nuts. 5. Remove the outside handle. 6. Disconnect electrical connector if required. 7. Remove actuator cable. 8. Remove the door lock cylinder. 9. Complete the necessary procedures: * For repair of a binding lock cylinder, refer to Binding Lock Cylinders. * For coding a new lock cylinder, refer to Key and Lock Cylinder Coding. Installation Procedure Important: When installing a new lock cylinder, apply GM P/N 12345120, or Canadian P/N 726548, lubricant or a similar lubricant to the inside of the lock case and the cylinder keyway. 1. Install the door lock cylinder. 2. Install the actuator cable. 3. Connect the electrical connector if required. 4. Install the handle assembly. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the outside handle mounting nuts. Tighten the nuts to 9 N.m (80 lb in). 6. Connect the lock cylinder rod to the rod clip. 7. Install the water deflector, as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Door Handle Replacement > Page 13043 8. Install the trim panel, as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door Rear Door Hinge: Service and Repair Door Hinge Pin and Bushing Replacement - Rear Door Door Hinge Pin and Bushing Replacement - Rear Door The door hinge pins and bushings are not replaceable. If the hinge pins or bushings are damaged, replace the door hinge as an assembly. Refer to Hinge Replacement - Front Door - Door Side and Hinge Replacement - Front Door - Body Side. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 13048 Rear Door Hinge: Service and Repair Hinge Replacement - Rear Cargo Door - Lower Body Side Hinge Replacement - Rear Cargo Door - Lower Body Side Removal Procedure 1. Visually inspect and restore as much of the damage as possible to factory specifications. 2. Remove all of the related panels and the components. 3. Remove any excess sealer surrounding the hinge. 4. Scribe the location of the hinge on the hinge pillar. 5. Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the pillar. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 13049 6. Center punch each of the 4 weld marks on the original hinge. 7. Locate and drill out all necessary factory welds in the rear body opening lower filler, using 8 mm (5/16 in) spot weld remover, in order to gain access to the backside of the lower hinge. Important: Use care when removing the filler panel. The filler panel must be reinstalled. 8. Carefully pry back the filler panel. 9. Remove rear body opening lower filler. If necessary, use a chisel in order to separate the filler from the opening. 10. Drill through the hinge only at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw or the equivalent. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 13050 11. If necessary, use a chisel in order to separate the hinge from the pillar. 12. Remove the hinge. 13. Remove all of the remaining weld from the pillar surface in order to ensure a flush fit of the service hinge. Installation Procedure 1. Repair any damage done to the pillar during the drilling or the removal. 2. Position the service hinge within the scribe marks on the pillar. 3. Center punch each bolt location on the pillar according to the service hinge. 4. Drill a 3 mm (1/8 in) pilot hole at each punch location. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 13051 5. Drill a 13 mm (1/2 in) hole at the pilot locations. 6. Clean and prepare all bare metal surfaces. Important: Prior to refinishing, refer to GM 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 7. Apply an approved anti-corrosion primer. 8. Apply full-body caulk to the entire hinge mounting surface. 9. Align the hinge with the holes in the pillar. Notice: Refer to Fastener Notice in Service Precautions. 10. Install the hinge fasteners. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 13052 Tighten the bolts to 25 N.m (18 lb ft). 11. Position the rear body opening lower filler and MIG weld in place at factory weld locations. 12. Clean and prepare all weld surfaces. 13. Refinish the metal surfaces as necessary. 14. Align and install all of the related panels and the components. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 13053 Rear Door Hinge: Service and Repair Hinge Replacement - Rear Cargo Door - Upper Body Side Hinge Replacement - Rear Cargo Door - Upper Body Side Removal Procedure 1. Visually inspect and restore as much of the damage as possible to factory specifications. 2. Remove all of the related panels and the components. 3. Remove any excess sealer surrounding the hinge. 4. Scribe the location of the hinge on the hinge pillar. 5. Locate and drill out all necessary factory welds in the hinge access panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 13054 6. Pry the access door out in order to gain access to the back side of the hinge. 7. Locate and drill the center of the hinge welds using a 13 mm (1/2 in) drill bit or the equivalent. 8. If necessary, use a chisel in order to separate the hinge from the pillar. 9. Remove the hinge. Installation Procedure 1. Clean and prepare the pillar surfaces in order to ensure a flush fit of the service hinge and the fasteners. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 13055 Important: Prior to refinishing, refer to GM 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 2. Apply an approved anti-corrosion primer. 3. Apply full-body caulk to the entire hinge mounting surface. 4. Position the service hinge within the scribe marks on the pillar. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the hinge fasteners. Tighten the bolts to 25 N.m (18 lb ft). 6. Refinish the metal surfaces as necessary. 7. Align and install all of the related panels and the components. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 13056 Rear Door Hinge: Service and Repair Hinge Replacement - Rear Door - Body Side Hinge Replacement - Rear Door - Body Side Removal Procedure 1. Remove all of the related panels and components. 2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar. 3. Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the door. Important: Punch the center of the weld so that as much of the weld as possible is removed during the drilling. 4. Center punch each of the 4 weld marks on the original hinge. Important: Do not drill into the hinge pillar. 5. Drill through the hinge only at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw or the equivalent. 6. Remove the hinge. If necessary, use a chisel in order to separate the hinge from the pillar. 7. Remove all of the remaining weld from the pillar surface in order to ensure a flush fit of the service hinge. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 13057 1. Repair any damage done to the pillar during the drilling or the removal. 2. Position the service hinge within the scribe marks on the pillar. 3. Center punch each stud location on the hinge pillar according to the service hinge (1). 4. Drill a 3 mm (1/8 in) pilot hole (2) at each center punch location. Important: The drill bit must be the exact size. 5. Drill an 11.5 mm (29/64 in) hole at the pilot locations for the studs. 6. Clean and prepare all of the bare metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to manufacturer's recommendations. 7. Apply an approved anti-corrosion primer. 8. Feed fish wire, GM P/N 15017229 of the equivalent, through the hinge (1), the hinge stud hole and out of the conduit hole in the pillar. 9. Install the stud, GM P/N 15017230, supplied with the service hinge, into the wire end. Pull the stud into position. 10. Hold the stud in position with the hinge and remove the fish wire. 11. Draw the stud (4) tight through the pillar. Use the nuts GM P/N 11516746, supplied. 12. Repeat steps 7 through 10 on the remaining stud locations. 13. Remove each service nut. 14. Apply a full-bodied caulk to the entire hinge mounting surface in order to ensure a proper seal. 15. Install the hinge (2) to the pillar (3). Use the supplied nuts (1). Notice: Refer to Fastener Notice in Service Precautions. 16. Install the hinge (2) to the pillar (3). Use the supplied nuts (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 13058 Tighten the hinge nuts (4) to 25 N.m (18 lb ft). 17. Clean and prepare all of the surfaces as necessary for refinishing. 18. Apply the sealers. Refinish the surfaces as necessary. 19. Install and align all of the related panels and the components. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 13059 Rear Door Hinge: Service and Repair Hinge Replacement - Rear Door - Door Side Hinge Replacement - Rear Door - Door Side Removal Procedure 1. Remove all of the related panels and components. 2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar. 3. Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the pillar. Important: It is critical to punch the center of the weld so that as much of the weld as possible is removed during the drilling. 4. Center punch each of the 4 weld marks on the original hinge. Important: Do not drill into the door (1). 5. Drill through the hinge (2), at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw (3) or equivalent. 6. Remove the hinge. If necessary, use a chisel in order to separate the hinge from the door. 7. Remove all of the remaining welds from the door surface in order to ensure a flush fit of the service hinge. Installation Procedure 1. Repair any damage done to the door during the drilling or the removal of the hinge. 2. Clean and prepare the backing plate mounting surfaces in order to ensure a flush fit of the backing plate. 3. Position the service hinge within the scribe marks on the door. 4. Center punch each hole location on the door according to the service hinge. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 13060 5. Drill a 3 mm (1/8 in) pilot hole at each center punch location. Important: Drill bit must be exact size. 6. Drill an 11.5 mm (29/64 in) hole at the pilot locations for the studs. 7. Clean and prepare all of the bare metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 8. Apply approved anti-corrosion primer. 9. Apply a full-bodied caulk to the entire hinge mounting surface in order to ensure a proper seal. Notice: Refer to Fastener Notice in Service Precautions. 10. Align the hinge (1) and the backing plate (4) with the holes in the door (2) and install the bolts (3). Tighten the hinge to the pillar nuts to 25 N.m (18 lb ft). 11. Clean and prepare all of the surfaces as necessary for refinishing. 12. Apply the sealers. Refinish the surfaces as necessary. 13. Install and align all of the related panels and the components. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Latch Replacement - Door (Cargo Door Lower) Rear Door Latch: Service and Repair Latch Replacement - Door (Cargo Door Lower) Latch Replacement - Door (Cargo Door Lower) Removal Procedure 1. Remove the bolts that retain the latch assembly to the door. 2. Disconnect electrical connector, if required. 3. Remove the actuator cable assembly from the latch. Installation Procedure 1. Install the actuator cable assembly to the latch. 2. Connect electrical connector, if required. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts that retain the latch assembly to the door. Tighten the bolts to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Latch Replacement - Door (Cargo Door Lower) > Page 13065 Rear Door Latch: Service and Repair Latch Replacement - Door (Cargo Door Upper) Latch Replacement - Door (Cargo Door Upper) Removal Procedure 1. Remove the door trim panel. 2. Remove the bolts that retain the latch to the door. 3. Remove latch from the door. 4. Remove the actuator cable assembly from the latch. 5. Remove the latch bolts. 6. Remove the latch from the door. Installation Procedure 1. Install the actuator cable assembly to the latch. 2. Install the latch assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Loose assemble the bottom 2 bolts. 1. Close door to self adjust latch assembly. Tighten bolts to 9 N.m (80 lb in). 2. Open the door. 3. Install the upper bolt. Tighten the bolt to 9 N.m (80 lb in). 4. Install the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Latch Replacement - Door (Cargo Door Lower) > Page 13066 Rear Door Latch: Service and Repair Latch Control Handle Replacement - Left Rear Door Latch Control Handle Replacement - Left Rear Door Removal Procedure 1. Remove the rear door trim panel, as necessary. 2. Pull back the water deflector, as necessary. Refer to Water Deflector Replacement. 3. Disconnect the lower latch cable from the handle. 4. Remove the latch control handle screws. 5. Remove the latch control handle. 6. Disconnect the upper latch cable from the handle. Installation Procedure 1. Connect the upper latch cable. 2. Install the latch control handle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the latch control handle screws. Tighten the screws to 9 N.m (80 lb in). 4. Connect the lower latch cable to handle. 5. Pull back the water deflector, as necessary. Refer to Water Deflector Replacement. 6. Install the rear door trim panel, as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Latch Replacement - Door (Cargo Door Lower) > Page 13067 Rear Door Latch: Service and Repair Lock Actuator Replacement - Door (Cargo Door) Lock Actuator Replacement - Door (Cargo Door) Removal Procedure 1. Remove the cargo door trim panel, as necessary. 2. Pull back the water deflector, as necessary. Refer to Water Deflector Replacement. 3. Remove the actuator lock control rod. 4. Disconnect the actuator wiring connector. 5. Remove the handle actuating cable. 6. Remove latch actuator cable. 7. Remove the bolts that retain the actuator assembly to the door. 8. Remove the actuator from the cargo door. Installation Procedure 1. Install the actuator to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the actuator assembly to the door. Tighten the bolts to 9 N.m (80 lb in). 3. Install the latch actuator cable. 4. Install the handle actuating cable. 5. Connect the actuator wiring connector. 6. Install the actuator lock control rod. 7. Pull back the water deflector, as necessary. Refer to Water Deflector Replacement. 8. Install the trim panel, as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Technical Service Bulletins > Customer Interest: > 01-08-64-015 > Oct > 01 > Side Access Door Squeak or Scraping Noise Rear Door Limiter: Customer Interest Side Access Door - Squeak or Scraping Noise File In Section: 08 - Body and Accessories Bulletin No.: 01-08-64-015 Date: October, 2001 TECHNICAL Subject: Front and Rear Side Access Door Noise (Replace Door Check Link) Models: 1999-2002 Chevrolet and GMC C/K Pickup Models (Silverado and Sierra) 2000-2002 Chevrolet and GMC C/K Utility Models (Avalanche, Suburban, Tahoe, Yukon, Yukon XL, Denali) 2001 GMC C3 Sierra 2002 Cadillac Escalade Condition Some customers may comment on a squeak or scraping type noise while opening the front and rear side access doors. Correction Replace the door check link on affected vehicles. Use the part numbers listed below. Refer to the Doors sub-section in the appropriate Service Manual for the Door Check Link Replacement procedure. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table as shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Limiter: > 01-08-64-015 > Oct > 01 > Side Access Door - Squeak or Scraping Noise Rear Door Limiter: All Technical Service Bulletins Side Access Door - Squeak or Scraping Noise File In Section: 08 - Body and Accessories Bulletin No.: 01-08-64-015 Date: October, 2001 TECHNICAL Subject: Front and Rear Side Access Door Noise (Replace Door Check Link) Models: 1999-2002 Chevrolet and GMC C/K Pickup Models (Silverado and Sierra) 2000-2002 Chevrolet and GMC C/K Utility Models (Avalanche, Suburban, Tahoe, Yukon, Yukon XL, Denali) 2001 GMC C3 Sierra 2002 Cadillac Escalade Condition Some customers may comment on a squeak or scraping type noise while opening the front and rear side access doors. Correction Replace the door check link on affected vehicles. Use the part numbers listed below. Refer to the Doors sub-section in the appropriate Service Manual for the Door Check Link Replacement procedure. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table as shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Limiter: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Adapter Kit: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Limiter: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 13086 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Limiter: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 13087 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Limiter: > Page 13088 Rear Door Limiter: By Symptom Technical Service Bulletin # 01-08-64-015 Date: 011001 Side Access Door - Squeak or Scraping Noise File In Section: 08 - Body and Accessories Bulletin No.: 01-08-64-015 Date: October, 2001 TECHNICAL Subject: Front and Rear Side Access Door Noise (Replace Door Check Link) Models: 1999-2002 Chevrolet and GMC C/K Pickup Models (Silverado and Sierra) 2000-2002 Chevrolet and GMC C/K Utility Models (Avalanche, Suburban, Tahoe, Yukon, Yukon XL, Denali) 2001 GMC C3 Sierra 2002 Cadillac Escalade Condition Some customers may comment on a squeak or scraping type noise while opening the front and rear side access doors. Correction Replace the door check link on affected vehicles. Use the part numbers listed below. Refer to the Doors sub-section in the appropriate Service Manual for the Door Check Link Replacement procedure. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table as shown. DISCLAIMER Technical Service Bulletin # 01-08-64-015 Date: 011001 Side Access Door - Squeak or Scraping Noise File In Section: 08 - Body and Accessories Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Limiter: > Page 13089 Bulletin No.: 01-08-64-015 Date: October, 2001 TECHNICAL Subject: Front and Rear Side Access Door Noise (Replace Door Check Link) Models: 1999-2002 Chevrolet and GMC C/K Pickup Models (Silverado and Sierra) 2000-2002 Chevrolet and GMC C/K Utility Models (Avalanche, Suburban, Tahoe, Yukon, Yukon XL, Denali) 2001 GMC C3 Sierra 2002 Cadillac Escalade Condition Some customers may comment on a squeak or scraping type noise while opening the front and rear side access doors. Correction Replace the door check link on affected vehicles. Use the part numbers listed below. Refer to the Doors sub-section in the appropriate Service Manual for the Door Check Link Replacement procedure. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table as shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair > Door Check Link Replacement - Rear Rear Door Limiter: Service and Repair Door Check Link Replacement - Rear REMOVAL PROCEDURE 1. Open the door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the body-side check strap bolt. 5. Remove the check strap plug. 6. Remove the door-side check strap nuts. 7. Pull the check strap from the inside of the door. INSTALLATION PROCEDURE 1. Install the check strap to the door. 2. Install the check strap to the body. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the check strap nuts. Tighten Tighten the nuts to 9 N.m (80 lb in). 4. Install the check strap bolt. Tighten Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair > Door Check Link Replacement - Rear > Page 13092 Tighten the bolt to 25 N.m (18 lb in). 5. Install the water deflector. 6. Install the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair > Door Check Link Replacement - Rear > Page 13093 Rear Door Limiter: Service and Repair Door Check Link Replacement Door Check Link Replacement Removal Procedure 1. Open the door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the body-side check strap bolt. 5. Remove the check strap plug. 6. Remove the door-side check strap nuts. 7. Pull the check strap from the inside of the door. Installation Procedure 1. Install the check strap to the door. 2. Install the check strap to the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the check strap nuts. Tighten the nuts to 9 N.m (80 lb in). 4. Install the check strap bolt. Tighten the bolt to 25 N.m (18 lb in). 5. Install the water deflector. 6. Install the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement Rear Door Panel: Service and Repair Panel Replacement Trim Panel Replacement - Rear Door Trim Panel Replacement - Rear Door Removal Procedure 1. Remove the upper trim panel. 2. Slide the trim panel upward to disengage the mounting hooks. 3. Remove the trim panel from the rear door. Installation Procedure 1. Position the trim panel to the liftgate. 2. Slide the trim panel downward to engage mounting hooks. 3. Install the upper trim panel. Trim Panel Replacement - Side Rear Door (Tahoe/Yukon/Escalade) Trim Panel Replacement - Side Rear Door (Tahoe/Yukon/Escalade) Removal Procedure 1. Remove the door handle bezel. 2. Remove the window-regulator handle, if equipped. 3. Remove the manual lock lever from the trim panel using a flat-bladed tool. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 13098 4. Remove the trim panel screws. 5. In order to remove the trim panel, slide the trim panel upward and outward in order to release the trim panel tab retainers. 6. Disconnect the electrical connectors, if necessary. Installation Procedure 1. Connect the electrical connectors, if necessary. Ensure that the electrical connectors are routed through the openings. 2. Align the tab retainers with the holes in the door. 3. Install the trim panel to the door by lowering the trim panel into the tab retainer holes in order to seat the retainers. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 2 trim panel screws. Tighten the 2 trim panel screws to 2 N.m (18 lb in). 5. Install the manual lock lever to the trim panel by pressing the lever until the lever is completely seated. 6. Install the window-regulator handle, as necessary. 7. Install the door handle bezel. Rear Side Door Trim Panel Replacement REMOVAL PROCEDURE 1. Remove the door handle bezel. 2. Remove the window-regulator handle, if equipped. 3. Remove the manual lock lever from the trim panel using a flat-bladed tool. 4. Remove the trim panel screws. 5. In order to remove the trim panel, slide the trim panel upward and outward in order to release the trim panel tab retainers. 6. Disconnect the electrical connectors, if necessary. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 13099 1. Connect the electrical connectors, if necessary. Ensure that the electrical connectors are routed through the openings. 2. Align the tab retainers with the holes in the door. 3. Install the trim panel to the door by lowering the trim panel into the tab retainer holes in order to seat the retainers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the 2 trim panel screws. Tighten Tighten the 2 trim panel screws to 2 N.m (18 lb in). 5. Install the manual lock lever to the trim panel by pressing the lever until the lever is completely seated. 6. Install the window-regulator handle, as necessary. 7. Install the door handle bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 13100 Rear Door Panel: Service and Repair Water Deflector Water Deflector Replacement Water Deflector Replacement Removal Procedure 1. Remove the rear door trim panel. 2. Using a flat-bladed tool, break the bond between the sealer and the door. 3. Pull off the water deflector from the inner door panel. Installation Procedure 1. Install the water deflector to the inner door panel. Use waterproof tape or 3M(R) 777 adhesive, as necessary. 2. Install the rear door trim panel. Water Deflector Replacement - Rear Door REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 13101 1. Remove the trim panel. 2. Remove inside door handle. 3. Note location of wiring and remove through deflector. 4. Using a flat-bladed tool, separate the bond between the sealer and the door. 5. Pull the waterproof sealing tape from the deflector. 6. Remove the water deflector. INSTALLATION PROCEDURE 1. Position the electrical connectors through the water deflector. 2. Using waterproof tape, or 3M(R) 777, or equivalent, install the water deflector to the door. 3. Install the trim panel to the door. Water Deflector Replacement - Rear Side Door REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 13102 1. Remove the rear door trim panel. 2. Using a flat-bladed tool, break the bond between the sealer and the door. 3. Pull off the water deflector from the inner door panel. INSTALLATION PROCEDURE 1. Install the water deflector to the inner door panel. Use waterproof tape or 3M(R) 777 adhesive, as necessary. 2. Install the rear door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair Rear Door Striker: Service and Repair Door Striker Replacement - Body Mounted Rear Removal Procedure 1. Remove the upper garnish trim panel. 2. Remove the striker screws. 3. Remove the striker. Installation Procedure 1. Install the striker to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the striker screws. Tighten the screws to 25 N.m (18 lb ft). 3. Install the upper garnish trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door - 1 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door - 1 REMOVAL PROCEDURE 1. Open the rear door. 2. Remove the rear door weatherstrip by pulling the weatherstrip from the track. 3. Release push-in retainers on lower weatherstrip from door. 4. Remove the rear door weatherstrip from the rear door. INSTALLATION PROCEDURE 1. Install the rear door weatherstrip on the rear door by pressing weatherstrip onto the track. 2. Install the rear door weatherstrip, by pressing in on the retainers until each retainer is fully seated. 3. Close the rear door. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door - 1 > Page 13110 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door - 2 TOOLS REQUIRED J 38778 Door Trim Pad Clip Remover REMOVAL PROCEDURE 1. Open the door. 2. Using the J 38778, remove the weatherstrip from the mounting surface. INSTALLATION PROCEDURE IMPORTANT: Apply the weatherstrip in an environment that is free from dust or dirt that could come into contact with the adhesive backing. Foreign material may cause improper adhesion. 1. Install the weatherstrip to the mounting surface by completing the following steps: 1.1. Peel off the backing paper. 1.2. Press the retainers into place. 2. Close the door. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door - 1 > Page 13111 Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip Replacement Weatherstrip Replacement - Rear Door Removal Procedure 1. Open the rear door. 2. Remove the rear door weatherstrip by pulling the weatherstrip from the track. 3. Release push-in retainers on lower weatherstrip from door. 4. Remove the rear door weatherstrip from the rear door. Installation Procedure 1. Install the rear door weatherstrip on the rear door by pressing weatherstrip onto the track. 2. Install the rear door weatherstrip, by pressing in on the retainers until each retainer is fully seated. 3. Close the rear door. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door - 1 > Page 13112 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Window Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. Installation Procedure 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window Rear Door Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Window REMOVAL PROCEDURE 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. INSTALLATION PROCEDURE 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 13118 Rear Door Window Glass Weatherstrip: Service and Repair Sealing Strip Replacement - Rear Door Window Belt Outer REMOVAL PROCEDURE IMPORTANT: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outer sealing strip from the door. INSTALLATION PROCEDURE 1. Align the sealing strip in place. Lower and press the strip into place. 2. Raise the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 13119 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Channel REMOVAL PROCEDURE 1. Remove the window. 2. Remove the window glass weatherstrip. 3. Remove the front window run channel top bolt. 4. Remove the front window run channel from the door. INSTALLATION PROCEDURE 1. Install the front window run channel to the door. 2. Install the front window run channel top bolt. Do not tighten the bolt 3. Install the window glass weatherstrip. 4. Install the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 13120 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. Installation Procedure 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 13121 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Rear Door Window Belt Outer Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outer sealing strip from the door. Installation Procedure 1. Align the sealing strip in place. Lower and press the strip into place. 2. Raise the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair Window Regulator Motor Replacement - Rear Door Removal Procedure 1. Raise the window. If the window motor is inoperable, remove the window to gain access to the window motor retaining screws. Refer to Window Replacement - Rear Door (Tahoe/Yukon/Escalade) Window Replacement - Rear Door (Suburban/Yukon XL/Avalanche/Escalade EXT). 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the door speaker. 5. Support the window. 6. Disconnect the wiring harness from the window regulator motor. 7. Remove the 3 bolts from the window motor located on the front side of the motor. Important: Do not allow the cable gear come out of the housing. A failure will result with the cable coming off the spool. 8. Separate the motor from the cable housing by wiggling the window motor. Observe the orientation of the window motor. 9. Remove the motor from the window regulator assembly. Installation Procedure 1. Install the motor to the cable housing by wiggling motor into place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts to the window motor. Tighten the bolts to 5 N.m (44 lb in). 3. Install the window, if removed. 4. Connect the wiring harness to the window regulator motor. 5. Remove the window support. 6. Connect the wire connector to the switch to inspect the operation of the window. 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Side Door Window Module Replacement Rear Door Window Regulator: Service and Repair Rear Side Door Window Module Replacement Module Replacement - Rear Power Window (Suburban/Yukon XL/Avalanche/Escalade EXT) Removal Procedure 1. Remove the trim panel. 2. Remove the water deflector. 3. Remove the Window glass. 4. Remove the window sash. 5. Remove the glass weatherstrip. 6. Remove the module from the door. Installation Procedure 1. Install the module to the door. 2. Install the glass weatherstrip. 3. Install the window sash. 4. Install the window glass. 5. Install the water deflector. 6. Install the trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Side Door Window Module Replacement > Page 13129 Rear Door Window Regulator: Service and Repair Window Regulator Motor Replacement - Rear Door Window Regulator Motor Replacement - Rear Door Removal Procedure 1. Raise the window. If the window motor is inoperable, remove the window to gain access to the window motor retaining screws. Refer to Window Replacement - Rear Door (Tahoe/Yukon/Escalade) Window Replacement - Rear Door (Suburban/Yukon XL/Avalanche/Escalade EXT). 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the door speaker. 5. Support the window. 6. Disconnect the wiring harness from the window regulator motor. 7. Remove the 3 bolts from the window motor located on the front side of the motor. Important: Do not allow the cable gear come out of the housing. A failure will result with the cable coming off the spool. 8. Separate the motor from the cable housing by wiggling the window motor. Observe the orientation of the window motor. 9. Remove the motor from the window regulator assembly. Installation Procedure 1. Install the motor to the cable housing by wiggling motor into place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts to the window motor. Tighten the bolts to 5 N.m (44 lb in). 3. Install the window, if removed. 4. Connect the wiring harness to the window regulator motor. 5. Remove the window support. 6. Connect the wire connector to the switch to inspect the operation of the window. 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Locations > Door Contact Plates - Rear Cargo Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Locations > Door Contact Plates - Rear Cargo > Page 13134 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Procedures Fuel Door: Procedures FUEL FILLER DOOR REPLACEMENT REMOVAL PROCEDURE 1. Open the fuel filler door. 2. Remove the screws from the fuel filler door. 3. Remove the push-pin retainer from the fuel filler door. 4. Reposition the filler neck assembly to the right. 5. Remove the screws from the fuel filler door. 6. Remove the fuel filler door. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Procedures > Page 13139 1. Position the fuel filler door to the quarter panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the fuel filler door. Tighten Tighten the screws to 9 N.m (80 lb in). 3. Reposition the fuel filler neck. 4. Install the screws to the fuel filler neck. Tighten Tighten the screws to 9 N.m (80 lb in). 5. Inspect the alignment of the fuel filler door Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Procedures > Page 13140 Fuel Door: Removal and Replacement Fuel Filler Door Replacement Removal Procedure 1. Open the fuel filler door. 2. Remove the screws from the fuel filler door. 3. Remove the push-pin retainer from the fuel filler door. 4. Reposition the filler neck assembly to the right. 5. Remove the screws from the fuel filler door. 6. Remove the fuel filler door. Installation Procedure 1. Position the fuel filler door to the quarter panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the fuel filler door. Tighten the screws to 9 N.m (80 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Procedures > Page 13141 3. Reposition the fuel filler neck. 4. Install the screws to the fuel filler neck. Tighten the screws to 9 N.m (80 lb in). 5. Inspect the alignment of the fuel filler door. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Technical Service Bulletins > Customer Interest for Hood Hinge: > 08-08-63-003 > Nov > 08 > Body - Replacement Fender Hood Hinge Hole Too Large Hood Hinge: Customer Interest Body - Replacement Fender Hood Hinge Hole Too Large INFORMATION Bulletin No.: 08-08-63-003 Date: November 26, 2008 Subject: Hood Hinge Pivot Hole Too Large On Some Replacement Fenders Models: 1999-2007 Chevrolet Silverado Classic 2001-2006 Chevrolet Avalanche, Suburban, Tahoe 1999-2007 GMC Sierra Classic 2001-2006 GMC Yukon Models Technicians installing GMSPO service replacement fenders may find that the fender side hood hinge pivot bolt attachment hole is too large (12 mm). The hood hinge pivot bolt attachment hole on some service fenders may be too large (12 mm), causing improper retention of the pivot bolt. To correct this condition, add a M8 X 32 mm O.D. X 2 mm thick washer between the hinge halves on the inboard side of the fender side hood hinge. This will provide the proper surface for the shoulder of the pivot bolt to contact as it is tightened. Refer to the illustration above. Parts Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Hinge: > 08-08-63-003 > Nov > 08 > Body Replacement Fender Hood Hinge Hole Too Large Hood Hinge: All Technical Service Bulletins Body - Replacement Fender Hood Hinge Hole Too Large INFORMATION Bulletin No.: 08-08-63-003 Date: November 26, 2008 Subject: Hood Hinge Pivot Hole Too Large On Some Replacement Fenders Models: 1999-2007 Chevrolet Silverado Classic 2001-2006 Chevrolet Avalanche, Suburban, Tahoe 1999-2007 GMC Sierra Classic 2001-2006 GMC Yukon Models Technicians installing GMSPO service replacement fenders may find that the fender side hood hinge pivot bolt attachment hole is too large (12 mm). The hood hinge pivot bolt attachment hole on some service fenders may be too large (12 mm), causing improper retention of the pivot bolt. To correct this condition, add a M8 X 32 mm O.D. X 2 mm thick washer between the hinge halves on the inboard side of the fender side hood hinge. This will provide the proper surface for the shoulder of the pivot bolt to contact as it is tightened. Refer to the illustration above. Parts Information Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Hood Hinge Replacement Hood Hinge: Service and Repair Hood Hinge Replacement Hood Hinge Replacement Removal Procedure 1. Remove the hood. 2. Remove the hinge to the hood bolts. 3. Remove the hinge from the hood. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the hinge to the hood bolts. Tighten the hinge to the hood bolts to 25 N.m (18 lb ft). 2. Install the hood. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Hood Hinge Replacement > Page 13158 Hood Hinge: Service and Repair Hood Link Replacement Hood Link Replacement Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Raise and support the front of the hood (1). 2. Remove the bolts (7) holding the hood link assembly to the hood hinge. 3. Remove the bolts (5) holding the hood link assembly to the fender. 4. Remove the hood link assembly from the vehicle. Installation Procedure 1. Position the hood link assembly (6) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolt (5) holding the hood link assembly to the fender. Tighten the link assembly to the fender bolt to 25 N.m (18 lb ft). 3. Install the fender bolt (7) holding the hood link assembly to the hood hinge. Tighten the hinge bolts to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair Hood Insulator / Pad: Service and Repair Hood Insulator Replacement Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Disconnect the underhood lamp harness electrical connector from the lamp assembly. 3. Remove the lamp harness fasteners from the underhood. 4. Depress the tab in order to remove the underhood lamp assembly. 5. Use the J 38778 in order to disengage the push-in retainers. 6. Gently pull on the hood insulator (1) in the center to slide out from behind the holding tabs (4). The insulator has a crease on the hood side to facilitate folding. Installation Procedure 1. Position the insulator (1) to the rear hood (3) and fold at the center to position under the front holding tabs (4). 2. Install the retainers (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair > Page 13162 3. Install the underhood lamp assembly and press the assembly in order to attach. 4. Install the fasteners to the underhood lamp harness. 5. Connect the electrical connector to the underhood lamp assembly. 6. Close the hood. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair Hood Latch: Service and Repair Hood Latch Replacement Removal Procedure 1. Raise the hood. 2. Remove the upper radiator support baffle. 3. Remove the bolts (2) from the hood release latch (1). 4. Disconnect the hood release cable end from the latch. 5. Remove the hood release latch from the vehicle. Installation Procedure 1. Connect the hood release cable end to the latch. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Page 13166 2. Install the hood latch (1) to the radiator support (3). 3. Install the hood latch bolts (2) loosely. 4. Adjust the hood latch height so that when the hood is closed, the hood is held securely against the front hood bumpers. Notice: Refer to Fastener Notice in Service Precautions. 5. Raise the hood. Tighten the hood latch bolts to 9 N.m (80 lb in). 6. Adjust the front hood bumpers so that the top of the hood is flush with the fenders. 7. Install the upper radiator support baffle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair Hood Latch Release Cable Replacement Removal Procedure Important: If the cable is broken, release the hood by pressing the latch tab on the left side of the lock assembly. Use a rod to press the latch tab. 1. Lift the hood. 2. Remove the left hinge pillar trim panel. 3. Remove the cable handle underneath the instrument panel (IP). 4. Remove the cable end from the handle. 1. Use needle nose pliers in order to squeeze the tabs in order to remove the cable end from the hood latch assembly. 2. Lift the cable from the lock. 5. Pull the cable in toward the cable handle through the hole in the cowl. 6. Detach the cable from the retainer clips. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 13170 7. Disconnect the cable end from the hood latch assembly. 1. Use needle nose pliers to squeeze the tabs in order to remove the cable end from the handle. 2. Lift the cable from the lock. Installation Procedure 1. Insert and pull the cable toward the front of the vehicle through the hole in the cowl. 2. Ensure that the grommet is seated. 3. Attach the cable end to the latch assembly. 4. Attach the cable to the retainer clips. 5. Attach the cable end to the cable handle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 13171 Notice: Refer to Fastener Notice in Service Precautions. 6. Attach the cable handle underneath the IP. Tighten the cable handle nut to 11 N.m (97 lb in). 7. Install the left hinge pillar trim panel. 8. Close the hood. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Stop > Component Information > Service and Repair Hood Stop: Service and Repair Hood Bumper Replacement Removal Procedure 1. Remove the front hood bumper by turning the front hood bumper (1) out counterclockwise. 2. Remove the side hood bumper by sliding the side hood bumper (2) rearward and pulling up. Installation Procedure 1. Install the side hood bumper by pushing down and sliding the side hood bumper (2) forward. 2. Install the front hood bumper (1) by turning the front hood bumper in clockwise until the hood closes flush with the fender. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Underhood Lamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13180 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13181 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13182 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13183 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13184 Underhood Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13185 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13186 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13187 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13188 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13189 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13190 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13191 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13192 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13193 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13194 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13195 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13196 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13197 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13198 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13199 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13200 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13201 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13202 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13203 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13204 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13205 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13206 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13207 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13208 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13209 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Removal Procedure Pull up on the rear hood seal and remove from the cowl pinch-weld flange. Installation Procedure Align the slot in the rear hood seal with the cowl pinch-weld flange and press into place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Window Replacement Liftgate Window Glass: Service and Repair Liftgate Window Replacement REMOVAL PROCEDURE 1. Open the liftgate window. 2. Support the liftgate window. 3. Disconnect the window defogger electrical connectors, if equipped. 4. Remove the liftgate window struts. 5. Open the liftgate in order to expose the liftgate window hinges. 6. With an assistant, remove the liftgate window hinge pin retainers from the hinge pins. 7. With an assistant, remove the liftgate window from the liftgate by sliding to the left. INSTALLATION PROCEDURE 1. Close the liftgate. 2. With an assistant, install the liftgate window to the liftgate by locating on pins and sliding to the right. 3. Open the liftgate. 4. With an assistant, install the new liftgate window hinge pin retainers. 5. Close the liftgate and open and support liftgate window. 6. Install the liftgate window struts. 7. Connect the liftgate window defogger electrical connectors, if equipped. 8. Remove the support and close window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Window Replacement > Page 13218 Liftgate Window Glass: Service and Repair Lift Window Panel Replacement Rear Lift Window Replacement Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Close the liftgate before removing the liftgate window. 2. Open the liftgate window. 3. Disconnect the rear defogger plug from the liftgate window. 4. Remove the struts from the liftgate window. Caution: Refer to Cracked Window Caution in Service Precautions. 5. With the aid of an assistant remove the window (1) from the closed liftgate. Remove the C-clips from the liftgate window hinges, NOT from the liftgate. 6. Slide the liftgate window toward the left of the vehicle and lift off. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Window Replacement > Page 13219 1. With the aid of an assistant install the liftgate window (1) to the vehicle. 2. Install the C-clips to the liftgate window hinges. 3. Install the struts to the liftgate window. 4. Connect the rear defogger plug to the liftgate window. 5. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 6. Close the liftgate window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams Door Lock Actuator - Cargo/Liftgate Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Service and Repair > Lock Actuator Replacement - Door (Cargo Door) Power Trunk / Liftgate Lock Actuator: Service and Repair Lock Actuator Replacement - Door (Cargo Door) REMOVAL PROCEDURE 1. Remove the cargo door trim panel, as necessary. 2. Pull back the water deflector, as necessary. 3. Remove the actuator lock control rod. 4. Disconnect the actuator wiring connector. 5. Remove the handle actuating cable. 6. Remove latch actuator cable. 7. Remove the bolts that retain the actuator assembly to the door. 8. Remove the actuator from the cargo door. INSTALLATION PROCEDURE 1. Install the actuator to the door. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the actuator assembly to the door. Tighten Tighten the bolts to 9 N.m (80 lb in). 3. Install the latch actuator cable. 4. Install the handle actuating cable. 5. Connect the actuator wiring connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Service and Repair > Lock Actuator Replacement - Door (Cargo Door) > Page 13225 6. Install the actuator lock control rod. 7. Pull back the water deflector, as necessary. Refer to Water Deflector Replacement. 8. Install the trim panel, as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Service and Repair > Lock Actuator Replacement - Door (Cargo Door) > Page 13226 Power Trunk / Liftgate Lock Actuator: Service and Repair Lock Actuator Replacement - Door (Liftgate) REMOVAL PROCEDURE 1. Remove the upper and lower trim panels. 2. Disconnect the electrical connectors. 3. Remove the cables attached to actuator assembly. 4. Remove the bolts from the latch actuator. 5. Remove the actuator from the liftgate. 6. Remove the lift gate lock cylinder. INSTALLATION PROCEDURE 1. Install the liftgate lock cylinder. 2. Install the actuator to the liftgate. 3. Loose assemble the bolts to the latch actuator. 4. Close the liftgate glass in order to adjust the actuator. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the cables to actuator assembly. Tighten Tighten the bolts to 9 N.m (80 lb in). 6. Connect the electrical connectors. 7. Install the upper and lower trim panels. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams Liftgate/Liftglass Ajar Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair Trunk / Liftgate Hinge: Service and Repair HINGE REPLACEMENT - REMOVABLE REAR PANEL - MID GATE REMOVAL PROCEDURE 1. Fold the rear seat back down. 2. Ensure the rear mid gate is in the upright position, latched. 3. Remove the hinge trim cover (1) from the mid-gate. 4. Remove the retaining nuts from the hinge. 5. Remove the hinge from the vehicle. INSTALLATION PROCEDURE 1. Install the hinge to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the four retaining nuts. Tighten Tighten the nuts to 25 N.m (18 lb ft). 3. Install the hinge trim cover (1) by pressing into place. 4. Fold the rear seat back up. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair Trunk / Liftgate Handle: Service and Repair LATCH CONTROL HANDLE REPLACEMENT - LEFT REAR DOOR REMOVAL PROCEDURE 1. Remove the rear door trim panel, as necessary. 2. Pull back the water deflector, as necessary. 3. Disconnect the lower latch cable from the handle. 4. Remove the latch control handle screws. 5. Remove the latch control handle. 6. Disconnect the upper latch cable from the handle. INSTALLATION PROCEDURE 1. Connect the upper latch cable. 2. Install the latch control handle. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the latch control handle screws. Tighten Tighten the screws to 9 N.m (80 lb in). 4. Connect the lower latch cable to handle. 5. Pull back the water deflector, as necessary. Refer to Water Deflector Replacement. 6. Install the rear door trim panel, as necessary. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair Trunk / Liftgate Interior Trim Panel: Service and Repair Trim Panel Replacement - Lift Gate Removal Procedure 1. Remove upper trim panel. 2. Pry gently with a thin-bladed tool in order to release the clips. 3. Slide the trim panel upward to disengage mounting hooks. 4. Remove the trim panel from the liftgate. Installation Procedure 1. Position the trim panel to vehicle. 2. Slide the trim panel downward to engage mounting hooks. 3. Install the upper trim panel. 4. Install the pull strap. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Door (Cargo Door Lower) Trunk / Liftgate Latch: Service and Repair Latch Replacement - Door (Cargo Door Lower) REMOVAL PROCEDURE 1. Remove the bolts that retain the latch assembly to the door. 2. Disconnect electrical connector, if required. 3. Remove the actuator cable assembly from the latch. INSTALLATION PROCEDURE 1. Install the actuator cable assembly to the latch. 2. Connect electrical connector, if required. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolts that retain the latch assembly to the door. Tighten Tighten the bolts to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Door (Cargo Door Lower) > Page 13243 Trunk / Liftgate Latch: Service and Repair Latch Replacement - Door (Cargo Door Upper) REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the bolts that retain the latch to the door. 3. Remove latch from the door. 4. Remove the actuator cable assembly from the latch. 5. Remove the latch bolts. 6. Remove the latch from the door. INSTALLATION PROCEDURE 1. Install the actuator cable assembly to the latch. 2. Install the latch assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Loose assemble the bottom 2 bolts. 3.1. Close door to sell adjust latch assembly. Tighten Tighten bolts to 9 N.m (80 lb in). 3.2. Open the door. 3.3. Install the upper bolt. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Door (Cargo Door Lower) > Page 13244 Tighten Tighten the bolt to 9 N.m (80 lb in). 4. Install the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Door (Cargo Door Lower) > Page 13245 Trunk / Liftgate Latch: Service and Repair Latch Replacement - Lift Gate Latch Replacement - Lift Gate Removal Procedure 1. Remove the latch assembly bolts (2). 2. Remove the latch assembly (4) from the liftgate. 3. Remove the electrical connector. 4. Remove the cable at latch. Installation Procedure 1. Install the cable at the latch. 2. Install the electrical connector. 3. Install the latch assembly (4) to the liftgate. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the latch assembly bolts (2). Tighten the bolts to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Door (Cargo Door Lower) > Page 13246 Trunk / Liftgate Latch: Service and Repair Latch Replacement - Removable Rear Window REMOVAL PROCEDURE 1. Remove the removable window panel. 2. Remove the trim panel (1) along the rear of the headliner. 3. Remove the latch retaining bolts. 4. Disconnect the electrical connector (2) from the latch. 5. Remove the latch from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connector (2) to the latch. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the latch retaining bolts. Tighten Tighten the bolts to 9 N.m (80 lb in). 3. Install the trim panel (1). 4. Install the removable window panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Door (Cargo Door Lower) > Page 13247 Trunk / Liftgate Latch: Service and Repair Lock Actuator Replacement - Door (Liftgate) Lock Actuator Replacement - Door (Liftgate) Removal Procedure 1. Remove the upper and lower trim panels. 2. Disconnect the electrical connectors. 3. Remove the cables attached to actuator assembly. 4. Remove the bolts from the latch actuator. 5. Remove the actuator from the liftgate. 6. Remove the lift gate lock cylinder. Installation Procedure 1. Install the liftgate lock cylinder. 2. Install the actuator to the liftgate. 3. Loose assemble the bolts to the latch actuator. 4. Close the liftgate glass in order to adjust the actuator. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the cables to actuator assembly. Tighten the bolts to 9 N.m (80 lb in). 6. Connect the electrical connectors. 7. Install the upper and lower trim panels. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Replacement - Lift Gate Removal Procedure 1. Remove the trim panel. 2. Remove the liftgate window latch assembly. 3. Depress the locking pin on the lock cylinder. 4. Turn lock cylinder counterclockwise. 5. Remove the liftgate lock cylinder from the latch assembly. Installation Procedure 1. Install the liftgate lock cylinder to the latch assembly. 2. Rotate lock cylinder clockwise until the pin engages. 3. Install the trim panel. 4. Install the liftgate window latch assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Strut Replacement - Liftgate Trunk / Liftgate Shock / Support: Service and Repair Strut Replacement - Liftgate Strut Replacement - Lift Gate Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Open and support the liftgate. Notice: Refer to Liftgate/Hood Assist Rod Notice in Service Precautions. 2. Lift up the retainer clips on the assist rods using a small flat-bladed tool. 3. Remove the upper end of the assist rods from the ball joint. 4. Remove the lower end of the assist rods from the ball joint. 5. Remove the assist rods from the liftgate. Installation Procedure 1. Position the assist rods to the liftgate. 2. Install the upper end of the assist rods to the ball joint. Press in to place until fully seated. 3. Install the lower end of the assist rods to the ball joint. Press in to place until fully seated. 4. Remove the support from the liftgate. 5. Close the liftgate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Strut Replacement - Liftgate > Page 13255 Trunk / Liftgate Shock / Support: Service and Repair Strut Replacement - Liftgate Window Strut Replacement - Lift Gate Window Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Open the liftgate window. 2. Support the liftgate window. Notice: Apply pressure only at the end of the hood assist rod that you are removing or attaching. Do NOT apply pressure to the middle of the rod because damage or bending will result. 3. Gently pry up the retaining clip in order to remove the lower end of the liftgate window strut from the ball stud on the liftgate. 4. Gently pry up the retaining clip in order to remove the lower end of the liftgate window strut from the ball stud on the window assembly. Installation Procedure 1. Push on the end of the strut in order to install the lower end of the liftgate window strut to the ball stud on the liftgate. 2. Push on the end of the strut in order to install the lower end of the liftgate window strut to the ball stud on the window assembly. 3. Close the liftgate window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Adjustments Trunk / Liftgate Striker: Adjustments Lock Striker Adjustment Removal Procedure 1. For lock striker adjustment procedures, refer to Lock Striker Replacement - End Gate (Tahoe/Yukon Adjustment) Lock Striker Replacement - End Gate (Tahoe/Yukon). 2. Adjust the lock striker accordingly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Adjustments > Page 13259 Trunk / Liftgate Striker: Service and Repair STRIKER REPLACEMENT - MIDGATE REMOVAL PROCEDURE 1. Fold down the rear seats. 2. Remove the rear removable glass panel. 3. Open the midgate to gain access to the striker. 4. Remove the striker bolts. 5. Remove the striker from the vehicle. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Ensure the mounting surface on the body is cleaned and free of any debris. 1. Install the striker. Tighten Tighten the striker bolts to 9 N.m (80 lb in). 2. Close the midgate. 3. Inspect for correct operation of the midgate. 4. Install the rear removable rear glass. 5. Return the rear seat to the upright position. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams Trunk / Liftgate Switch: Diagrams Cargo Door Ajar Switch Cargo Door Key Switch - Security - RH Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Page 13263 Liftgate Key Switch - Security Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Mid Gate - Lower Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Mid Gate - Lower Weatherstrip Replacement - Mid Gate - Lower Removal Procedure 1. Fold down the rear seat. 2. Remove the rear removable glass panel. 3. Remove the midgate. 4. Remove the floor hinge molding. 5. Starting from one end remove the weatherstrip from the vehicle. Installation Procedure Important: To begin the installation of the weatherstrip, ensure the weatherstrip is at a minimum of 21°C (70°F). 1. Starting from one end of the weatherstrip, install the weatherstrip. 2. Ensure the corners of the weatherstrip are fully seated. 3. Install the floor hinge molding. 4. Install the midgate. 5. Close the midgate. 6. Install the rear removable rear glass panel. 7. Inspect the weatherstrip when the midgate is closed and the glass panel installed. 8. Set the rear seat in the upright position. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Mid Gate - Lower > Page 13268 Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Mid Gate - Upper Weatherstrip Replacement - Mid Gate - Upper Removal Procedure 1. Fold down the rear seat. 2. Remove the rear removable glass panel. 3. Remove the midgate. 4. Starting from one end, remove the weatherstrip from the vehicle. Installation Procedure Important: To begin the installation of the weatherstrip, ensure the weatherstrip is at a minimum of 21°C (70°F). 1. Starting from one end of the weatherstrip, install the weatherstrip. 2. Ensure the corners of the weatherstrip are fully seated. 3. Install the midgate. 4. Close the midgate. 5. Install the rear removable rear glass panel. 6. Inspect the weatherstrip when the midgate is closed and the glass panel installed. 7. Set the rear seat in the upright position. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Mid Gate - Lower > Page 13269 Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Lift Gate Weatherstrip Replacement - Lift Gate Removal Procedure 1. Open the liftgate. 2. Remove the weatherstrip molding from the pinch- weld flange: 1. Firmly grip the weatherstrip. 2. Carefully pull the weatherstrip out and away from the vehicle. Installation Procedure 1. Align paint mark on the weather-strip to outer top center of pinch weld flange. 2. Push the weather-strip onto the pinch weld flange, beginning from the top center of the endgate opening. 3. Completely seat the weather-strip around the liftgate opening. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Mid Gate - Lower > Page 13270 Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Compartment Opening Weatherstrip Replacement - Rear Compartment Opening Removal Procedure 1. Open the door(s). 2. Remove 7 bolts retaining weatherstrip assembly to body. Installation Procedure 1. Install the weatherstrip assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install 7 bolts retaining weatherstrip assembly to body. Tighten the bolts to 2 N.m (18 lb in). 3. Close the door(s). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem/Nameplate Replacement - Door Body Emblem: Service and Repair Emblem/Nameplate Replacement - Door Emblem/Nameplate Replacement - Door Tools Required J 25070 Heat Gun Removal Procedure Important: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the door emblem. 2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Remove the emblem/nameplate from the door surface using a plastic, flat-bladed tool. 5. Remove all adhesive from the door panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the door surface using varnish makers and painters (VMP) naptha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked apply tape. 2. Warm the door surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the door panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the door panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the door emblem. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem/Nameplate Replacement - Door > Page 13278 Body Emblem: Service and Repair Emblem/Nameplate Replacement - End Gate Emblem/Nameplate Replacement - End Gate Tools Required J 25070 Heat Gun Removal Procedure Important: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the endgate emblem. 2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Remove the emblem/nameplate from the endgate surface using a plastic, flat-bladed tool. 5. Remove all adhesive from the endgate panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the endgate surface using varnish makers and painters (VMP) naptha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked apply tape. 2. Warm the endgate surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the endgate panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the endgate panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the endgate emblem. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem/Nameplate Replacement - Door > Page 13279 Body Emblem: Service and Repair Emblem/Nameplate Replacement - Pickup Box Emblem/Nameplate Replacement - Pickup Box Tools Required J 25070 Heat Gun Removal Procedure Important: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the pickup box emblem. 2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Remove the emblem/nameplate from the pickup box surface using a plastic, flat-bladed tool. 5. Remove all adhesive from the pickup box panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the pickup box surface using varnish makers and painters (VMP) naptha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked apply tape. 2. Warm the pickup box surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the pickup box panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the pickup box panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the pickup box emblem. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem/Nameplate Replacement - Door > Page 13280 Body Emblem: Service and Repair Emblem/Nameplate Replacement - Pickup Cab Emblem/Nameplate Replacement - Pickup Cab Tools Required J 25070 Heat Gun Removal Procedure Important: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the pickup cab emblem. 2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Remove the emblem/nameplate from the pickup cab surface using a plastic, flat-bladed tool. 5. Remove all adhesive from the pickup cab panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the pickup cab surface using varnish makers and painters (VMP) naptha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked apply tape, using the dimensions in the graphic. 2. Warm the pickup cab surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the pickup cab panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the pickup cab panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the pickup cab emblem. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the wiper arms. 2. Pull up in order to release the outboard air inlet grille panel clips. 3. Remove the attaching clips running along the edges of the center air inlet grille panel. 4. Remove the sheet metal screws on each end of the air inlet grille panel. 5. Disconnect the windshield washer hose from the nozzle underneath the center air inlet grille panel. 6. Remove the air inlet grille panel. Installation Procedure 1. Connect the windshield washer hose to the nozzle under the center air inlet grille panel. 2. Position the air inlet grille panel to the vehicle and attach the clips to the edges of the center air inlet grille panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the sheet metal screws on each end of the air inlet grille panel. Tighten the sheet metal screws to 2 N.m (18 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Page 13284 4. Align the outboard air inlet grille panel clips and press down in order to install. 5. Install the wiper arms. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Frame > Component Information > Technical Service Bulletins > Customer Interest for License Plate Frame: > 02-08-66-004 > Apr > 02 > Liftgate - License Plate Housing Paint Rubs Through License Plate Frame: Customer Interest Liftgate - License Plate Housing Paint Rubs Through File In Section: 08 - Body and Accessories Bulletin No.: 02-08-66-004 Date: April, 2002 TECHNICAL Subject: Paint Rub Through on Liftgate Around Edge of License Plate Housing/Pocket (Install Insulating Seal/Gasket) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada Condition Some customers may comment that the paint on the liftgate around the edges of the license plate housing or pocket appears to be rubbing through or wearing off. Cause Changes in temperature may cause the plastic license plate housing to expand and contract. When this occurs, the license plate housing comes in contact with or rubs against the paint surface on the liftgate. Correction Remove the license plate housing from the liftgate. Refer to the License Plate Pocket Replacement procedure in the Service Manual (SI2000 Document ID # 740995). Install an insulating perimeter seal or gasket on the backside edge of the housing as shown. When properly installed, the seal (1) will start at one side of the liftgate release handle (2) and go completely around the housing stopping at the other side of the handle. Do NOT attempt to install the seal on the liftgate housing directly below the release handle. Once installed, it may be necessary to trim off any excess seal material. Parts Information Parts are expected to be available 4-22-2002 from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Frame > Component Information > Technical Service Bulletins > Customer Interest for License Plate Frame: > 02-08-66-004 > Apr > 02 > Liftgate - License Plate Housing Paint Rubs Through > Page 13293 For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for License Plate Frame: > 02-08-66-004 > Apr > 02 > Liftgate - License Plate Housing Paint Rubs Through License Plate Frame: All Technical Service Bulletins Liftgate - License Plate Housing Paint Rubs Through File In Section: 08 - Body and Accessories Bulletin No.: 02-08-66-004 Date: April, 2002 TECHNICAL Subject: Paint Rub Through on Liftgate Around Edge of License Plate Housing/Pocket (Install Insulating Seal/Gasket) Models: 2002 Chevrolet and GMC S/T Utility Models (TrailBlazer, Envoy) 2002 Oldsmobile Bravada Condition Some customers may comment that the paint on the liftgate around the edges of the license plate housing or pocket appears to be rubbing through or wearing off. Cause Changes in temperature may cause the plastic license plate housing to expand and contract. When this occurs, the license plate housing comes in contact with or rubs against the paint surface on the liftgate. Correction Remove the license plate housing from the liftgate. Refer to the License Plate Pocket Replacement procedure in the Service Manual (SI2000 Document ID # 740995). Install an insulating perimeter seal or gasket on the backside edge of the housing as shown. When properly installed, the seal (1) will start at one side of the liftgate release handle (2) and go completely around the housing stopping at the other side of the handle. Do NOT attempt to install the seal on the liftgate housing directly below the release handle. Once installed, it may be necessary to trim off any excess seal material. Parts Information Parts are expected to be available 4-22-2002 from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for License Plate Frame: > 02-08-66-004 > Apr > 02 > Liftgate - License Plate Housing Paint Rubs Through > Page 13299 For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Molding Replacement - Rear Body Side - Lower Front Lower Side Moulding / Trim: Service and Repair Molding Replacement - Rear Body Side - Lower Front Molding Replacement - Rear Body Side - Lower Front Removal Procedure Important: When any molding is removed, all retaining clips must be replaced if the molding is to be reused. 1. Remove all retaining screws. 2. Grasp the lower part of the molding. 3. Pull outward in order to release the clips from the body panel. Installation Procedure 1. Use a 3M(TM) Scotch Brite molding adhesive remover disc, P/N 07501, or equivalent, in order to remove any adhesive tape on the body panel. 2. Remove the protective lining of the adhesive tape. 3. Align the retaining clips in the respective holes. 4. Press firmly on the molding until all of the retaining clips are completely seated. 5. Press on the top part of the molding so that the tape adheres to the body panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Molding Replacement - Rear Body Side - Lower Front > Page 13304 Lower Side Moulding / Trim: Service and Repair Molding Replacement - Rear Body Side - Lower Rear Molding Replacement - Rear Body Side - Lower Rear Removal Procedure Important: When any molding is removed, all retaining clips must be replaced if the molding is to be reused. 1. Remove the retaining screw (1). 2. Grasp the lower part of the molding. 3. Pull outward in order to release the clips from the body panel. Installation Procedure 1. Use a 3M(TM) Scotch Brite molding adhesive remover disc, P/N 07501, or equivalent, in order to remove any adhesive tape on the body panel. 2. Remove the protective lining of the adhesive tape. 3. Align the retaining clips in the respective holes. 4. Press firmly on the molding until all of the retaining clips are completely seated. 5. Press on the top part of the molding so that the tape adheres to the body panel. 6. Install the retaining screw (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair Windshield Moulding / Trim: Service and Repair Stationary Window Reveal Molding Repair Stationary Window Reveal Molding Repair Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: The window reveal molding fills the cavity between the body and window. If the reveal molding is stretched or damaged, it cannot be reused and it must be replaced. 1. Lift up on the loose area of the reveal molding. 2. Clean the top edge of the window surface and the reveal molding with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint-free cloth. 3. If the reveal molding cannot be reused, refer to Urethane Adhesive Installation of Stationary Windows. Installation Procedure Caution: Refer to Window Retention Caution in Service Precautions. 1. Verify all primers and urethane adhesive are within expiration dates. Important: Use care when applying the prep, clear #1, to the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly. 2. Use a new dauber in order to apply glass prep, clear #1, to the channel area approximately 13 mm (1/2 in) to the upper edge of the window. 3. Wipe the glass primed area immediately with a clean lint-free cloth. 4. Shake the glass primer, black #2, for at least 1 minute. 5. Use a new dauber in order to apply glass primer, black #2, to the top edge of the window. 6. Apply a small bead of urethane adhesive (2) between the window (1) and the pinch-weld. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 13309 7. Reinstall the window reveal molding. 1. Start from the loose area and hand-press the reveal molding into place over the edge of the window. 2. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. 3. Tape should be applied in order to retain the reveal molding to the window. This will maintain a flush fit with the body. 4. The tape is to be removed after 6 hours. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 13310 Windshield Moulding / Trim: Service and Repair Windshield Side Reveal Molding Replacement Windshield Side Reveal Molding Replacement Removal Procedure 1. Pull back the front door sealing weatherstrip (1) to expose the windshield reveal molding screws. 2. Remove the screws from the windshield reveal molding. 3. Remove the windshield reveal molding from the windshield pillar. Installation Procedure 1. Install the windshield reveal molding to the windshield pillar. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the windshield reveal molding. Tighten the screws to the windshield reveal molding to 2 N.m (18 lb in). 3. Install the front door sealing weatherstrip (1) to the pinch-weld. 4. Close the door. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 13311 Windshield Moulding / Trim: Service and Repair Windshield Upper Reveal Molding Replacement Windshield Upper Reveal Molding Replacement Tools Required * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Plastic Paddle Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. 1. Remove both right and left sides of the reveal molding. Important: The windshield reveal molding fills the cavities between the body and windshield. If the reveal molding is stretched or damaged, replace the molding. 2. Remove the upper windshield reveal molding. 1. Use a flat-bladed tool in order to carefully pry the end of the upper reveal molding out about 76 mm (3 in). 2. Grasp the corner of the windshield reveal molding by hand or use a suitable tool to slowly pull the molding away from the windshield. 3. If the molding will not release, use a utility knife to release the molding. Installation Procedure 1. Clean the top edge of the windshield surface with a 50/50 mixture of isopropyl alcohol and water on a dampened lint-free cloth. 2. Fit the new reveal molding to the windshield prior to installation. Caution: Refer to Window Retention Caution in Service Precautions. 3. Verify that all primers and urethane adhesive are within expiration dates. Important: Apply the prep (clear #1) to the windshield carefully. The primer dries almost instantly, and may stain the viewing area of the windshield if not applied evenly. 4. Use a new dauber in order to apply glass prep (clear #1) to the channel area approximately 13 mm (1/2 in) to the upper edge of the windshield. 5. Wipe the glass primed area immediately with a clean lint-free cloth. 6. Shake the glass primer (black #2) for at least 1 minute. Use a new dauber to apply the primer to the top edge of the windshield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 13312 7. Apply a small bead of urethane adhesive (2) between the windshield (1) and the pinchweld. 8. Install the upper reveal molding. 1. Start from the center and hand-press the reveal molding into place over the edge of the windshield. 2. Install the right and the left sides of the reveal molding. 3. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. 4. Apply the tape in order to retain the reveal molding to the windshield. This will maintain a flush fit with the body. 5. Remove the tape after 6 hours. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair Wheelhouse Panel Replacement Removal Procedure 1. Remove the push-in retainers (2) from the wheelhouse panel. 2. Remove the retainers (2) from the front fascia (1). If applicable. 3. Remove the top clips retaining the harness to the top of the wheelhouse panel. 4. Remove the wheelhouse panel from the wheelhouse. Installation Procedure 1. Install the wheelhouse panel to the wheelhouse. 2. Install the push-in retainers (2) to the wheelhouse panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Page 13318 3. Install the retainers (2) to the front fascia (1). If applicable. 4. Install the top clips retaining the harness to the top of the wheelhouse panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Frame Cushion or Insulator Replacement (Regular Cab) Body / Frame Mount Bushing: Service and Repair Frame Cushion or Insulator Replacement (Regular Cab) Frame Cushion or Insulator Replacement (Regular Cab) Removal Procedure Important: Ensure that the vehicle is unloaded prior to body removal. 1. Remove the front bumper. 2. Remove the front lamp harness ground bolt (1). 3. Remove the master cylinder. Perform the following steps: 1. Remove the nuts retaining the master cylinder to the brake booster. 2. Remove the master cylinder from the brake booster. 3. Secure the cylinder away from the booster. 4. Raise the vehicle on the hoist. Refer to Vehicle Lifting. 5. Remove the running boards, if equipped. 6. Remove the park brake equalizer intermediate cable. Perform the following steps: 1. Remove the nut from the park brake equalizer intermediate cable. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 7. Remove the body mount bolts. 8. Properly support the body in the area that the mounts will be replaced. Caution: When you remove the body cushions, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result if you do not follow the guides outlined below: * Intermediate steering shaft-Do not allow the shaft to extend more than 25 mm (1 in). * Fuel tank filler hose-Do not stretch the hose excessively. * Tail/Turn signal lamp wiring/rear lamps junction block-Leave slack in the wires. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Frame Cushion or Insulator Replacement (Regular Cab) > Page 13324 * Park brake cable-Leave slack in the cable. * Body ground straps-Leave slack in the wire. Lower the chassis accordingly in order to remove the cushions (1) as necessary. Installation Procedure 1. Install the cushions (1) as necessary and raise the chassis accordingly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the body mount bolts. Tighten the bolts to 85 N.m (63 lb ft). 3. Install the park brake equalizer intermediate cable. Perform the following steps: 1. Pull rearward on the park brake cable to the original position. 2. Secure the cable retaining tabs to the frame. 3. Install the intermediate cable end to the equalizer. 4. Install the nut to the threaded end of the intermediate cable. Tighten the nut to 3.5 N.m (31 lb in). 4. Install the running boards, if equipped. Refer to Assist Step Replacement (Denali) Assist Step Replacement (Escalade) Assist Step Replacement (Z-71). 5. Lower the vehicle. 6. Install the master cylinder. Perform the following steps: 1. Mount the master cylinder to the brake booster. 2. Install the master cylinder mounting nuts. Tighten the nuts to 36 N.m (27 lb ft). 7. Install the front lamp harness ground bolt (1). Tighten the bolt to 6 N.m (53 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Frame Cushion or Insulator Replacement (Regular Cab) > Page 13325 8. Install the front bumper. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Frame Cushion or Insulator Replacement (Regular Cab) > Page 13326 Body / Frame Mount Bushing: Service and Repair Frame Cushion or Insulator Replacement (Extended Cab) Frame Cushion or Insulator Replacement (Extended Cab) Removal Procedure Important: Ensure that the vehicle is unloaded prior to body removal. 1. Remove the front bumper. 2. Remove the front lamp harness ground bolt (1). 3. Remove the master cylinder. Perform the following steps: 1. Remove the nuts retaining the master cylinder to the brake booster. 2. Remove the master cylinder from the brake booster. 3. Secure the cylinder away from the booster. 4. Raise the vehicle on the hoist. Refer to Vehicle Lifting. 5. Remove the running boards, if equipped. 6. Remove the park brake equalizer intermediate cable. Perform the following steps: 1. Remove the nut from the park brake equalizer intermediate cable. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 7. Remove the body mount bolts. 8. Properly support the body in the area that the mounts will be replaced. Caution: When you remove the body cushions, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result if you do not follow the guides outlined below: * Intermediate steering shaft-Do not allow the shaft to extend more than 25 mm (1 in). * Fuel tank filler hose-Do not stretch the hose excessively. * Tail/Turn signal lamp wiring/rear lamps junction block-Leave slack in the wires. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Frame Cushion or Insulator Replacement (Regular Cab) > Page 13327 * Park brake cable-Leave slack in the cable. * Body ground straps-Leave slack in the wire. Lower the chassis accordingly in order to remove the cushions (1) as necessary. Installation Procedure 1. Install the cushions (1) as necessary and raise the chassis accordingly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the body mount bolts. Tighten the bolts to 85 N.m (63 lb ft). 3. Install the park brake equalizer intermediate cable. Perform the following steps: 1. Pull rearward on the park brake cable to the original position. 2. Secure the cable retaining tabs to the frame. 3. Install the intermediate cable end to the equalizer. 4. Install the nut to the threaded end of the intermediate cable. Tighten the nut to 3.5 N.m (31 lb in). 4. Install the running boards, if equipped. 5. Lower the vehicle. 6. Install the master cylinder. Perform the following steps: 1. Mount the master cylinder to the brake booster. 2. Install the master cylinder mounting nuts. Tighten the nuts to 36 N.m (27 lb ft). 7. Install the front lamp harness ground bolt (1). Tighten the bolt to 6 N.m (53 lb in). 8. Install the front bumper. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Body/Frame - Revised Crossmember/Body Bolt Service Cross-Member: Technical Service Bulletins Body/Frame - Revised Crossmember/Body Bolt Service Bulletin No.: 05-08-61-005 Date: April 29, 2005 SERVICE MANUAL UPDATE Subject: Revised Crossmember/Body Mount Bolt Installation Information Models: 1999-2005 Cadillac Full-Size Pickup and Utility Models 1999-2005 Chevrolet Full-Size Pickup and Utility Models 1999-2005 GMC Full-Size Pickup and Utility Models This bulletin is being issued to revise all repair procedures that include reinstalling the front engine crossmember-to-frame bolts or any body mount bolts in the Frame and Underbody sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Before reinstalling front engine crossmember-to-frame bolts or any body mount bolts, you must do the following: 1. Remove all traces of the original thread locking material. 2. Clean the threads of the bolt with denatured alcohol, or equivalent, and allow to dry. 3. Apply Thread locker, P/N 12345493, (Canadian P/N 10953488). Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Engine Front Crossmember Replacement (4WD) Cross-Member: Service and Repair Engine Front Crossmember Replacement (4WD) Engine Front Crossmember Replacement (4WD) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the differential carrier shield. 3. Remove the bolts retaining the crossmember to the frame. 4. Remove the crossmember from the vehicle. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Engine Front Crossmember Replacement (4WD) > Page 13334 1. Install the crossmember to the vehicle. 2. Perform the following procedure before installing the bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Notice: Refer to Fastener Notice. 3. Install the bolts retaining the crossmember to the frame. Tighten the crossmember retaining bolts to 120 N.m (88 lb ft). 4. Install the differential carrier shield. 5. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Engine Front Crossmember Replacement (4WD) > Page 13335 Cross-Member: Service and Repair Transmission Support Replacement Transmission Support Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Remove the nut retaining the transmission mount to the transmission support. 4. Raise the rear of the transmission. 5. Remove the bolts and the nuts retaining the transmission support to the frame. (15 series) 6. Remove the bolts and the nuts retaining the transmission support to the frame. (25/35 series) 7. Remove the transmission support from the frame. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Engine Front Crossmember Replacement (4WD) > Page 13336 1. Install the transmission support to the frame. (15 series) 2. Install the transmission support to the frame. (25/35 series) Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts and the nuts in order to retain the transmission support to the frame. Tighten the nuts to 95 N.m (70 lb ft). 4. Lower the rear of the transmission. 5. Install the transmission mount to the transmission support. 6. Install the nuts in order to retain the transmission mount to the transmission support. Tighten the nuts to 50 N.m (36 lb ft). 7. Remove the transmission jack. 8. Lower the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Customer Interest for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Adapter Kit: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Customer Interest for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 13345 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Customer Interest for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 13346 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Adapter Kit: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 13352 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 13353 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Replacement Removal Procedure 1. Disconnect the trailer wiring harness. 2. Remove the hitch platform bolts from the frame rails and the rear bumper. 3. Remove the hitch platform from the vehicle. Installation Procedure 1. Position the hitch platform to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the platform hitch bolts to the frame rails and the rear bumper. Tighten the bolts to 125 N.m (92 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 13357 3. Connect the trailer wiring harness. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair Grille Replacement (Avalanche) Removal Procedure 1. For diesel only, remove the winter cover, if equipped and installed. 2. Open the hood. 3. Remove the push-pin retainers (1) from the radiator support. 4. Pull in order to release the radiator grille from the support reinforcement. 5. Pull at each location in order to release the retainer clips of the grille ends from the fender. Remove the grille from the vehicle. Installation Procedure 1. Align the grille to the grille support and the fenders. 2. Press the grille ends in order to secure the grille to the fender. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Page 13361 3. Align the radiator grille to the support reinforcement. 4. Install the push pin retainers (1) to the radiator support. 5. Close the hood. 6. Inspect the grille for proper alignment. 7. For diesel only, install the winter cover, if removed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement Arm Rest: Service and Repair Armrest Replacement Armrest Replacement Removal Procedure 1. Remove the door trim panel. 2. Remove the armrest retaining screws. 3. Remove the armrest from the panel. Installation Procedure 1. Install the armrest from the panel. 2. Install the armrest retaining screws. 3. Install the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement > Page 13367 Arm Rest: Service and Repair Armrest Replacement - Door REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the armrest retaining screws. 3. Remove the armrest from the panel. INSTALLATION PROCEDURE 1. Install the armrest from the panel. 2. Install the armrest retaining screws. 3. Install the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement > Page 13368 Arm Rest: Service and Repair Armrest Replacement - Front Seat ARMREST REPLACEMENT - FRONT SEAT REMOVAL PROCEDURE 1. Set the front seat back in the forward position. 2. Separate the J-clip at the bottom of the seat using a flat bladed tool. 3. Remove the 2 push pins at the bottom retaining the seat back cover to the card board. 4. From the back of the front seat, disconnect the heating element wire connector, if equipped. 5. Role up the seat cover Lip to the bottom of the arm rest. 6. Recline the seat. 7. From the front of the seat move the seat cushion away from the seat frame to gain access to the arm rest clip. 8. Remove the rubber band from the clip. 9. Remove the clip from the seat frame. 10. Remove the arm rest by pulling outwards. INSTALLATION PROCEDURE 1. Install the clip in the slot of the seat frame. 2. Install the rubber band on the clip to retain it in place. 3. Fold down the seat cover. 4. Install the arm rest by pressing in until it is fully seated. 5. Connect the heating element wire connector. 6. Set the front seat back in the forward position. 7. Pull down on the seat cover in order to install the 2 push pins retaining the seat back to the card board. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement > Page 13369 8. Connect the J-clip at the bottom of the seat. 9. Push on the seat back cover to ensure the cover is held in place by the velcro. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement > Page 13370 Arm Rest: Service and Repair Armrest Replacement - Rear Seat Armrest Replacement - Rear Seat Removal Procedure 1. Fold the right side of the rear seat forward to gain access to the armrest trim cover and bolts. 2. Remove the armrest trim cover (7). 3. Remove the armrest bolts (6). 4. Remove the armrest by sliding off the pivot and out. Installation Procedure 1. Install the rear seat armrest to the pivot point on the rear seat. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the armrest bolts (6). Tighten the bolts to 9 N.m (80 lb ft). 3. Install the armrest trim cover (7) and screws (8). 4. Fold the right rear seat back into the upright position. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair Ash Tray: Service and Repair Ashtray Replacement Removal Procedure 1. Remove the ashtray from the instrument panel (IP) by depressing the tab and sliding the ashtray rearward. 2. Remove the lower IP trim panel. 3. Remove the ashtray lamp wiring harness from the ashtray housing. 4. Remove the screws holding the ashtray housing to the rear of the IP lower trim panel. 5. Remove the ashtray housing from the lower trim housing. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Page 13374 1. Install the ashtray housing to the lower IP trim panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws holding the ashtray housing to the rear of the IP lower trim panel. Tighten the ashtray housing screws to 2 N.m (18 lb in). 3. Connect the ashtray lamp wiring harness to the ashtray housing. 4. Install the lower IP trim panel. 5. Insert the ashtray to the IP by depressing the tab and sliding the ashtray forward. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Cargo Cover > Component Information > Service and Repair Cargo Cover: Service and Repair CARGO COVER COMPRESSION LATCH REPLACEMENT REMOVAL PROCEDURE 1. Lower the end gate. 2. Remove the cargo cover assembly from the vehicle. 3. Remove the latch fastener. 4. Remove the latch from the cargo cover. INSTALLATION PROCEDURE 1. Install the latch to the cargo cover. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fasteners to the latch. Tighten Tighten the fasteners to 6 N.m (53 lb in). 3. Install the rear compartment cover assembly to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 13382 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 13383 Carpet: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 13384 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 13385 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures Carpet: Procedures Eliminating Unwanted Odors in Vehicles Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, US P/N 12378554, US AC-Delco 88900909, Canadian P/N 88901678, may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a persistent or recurring odor, you may call to obtain additional information and usage suggestions. Floor Carpet Drying Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 13388 Carpet: Removal and Replacement Carpet Replacement - Front (Utility) Carpet Replacement - Front (Utility) Removal Procedure 1. Remove the front seats. 2. Remove the rear seats. 3. Remove the front center seat. 4. Remove the floor center console, if equipped. 5. Remove the lower bracket from the IP to the floor to allow carpet removal. 6. Remove the door sill trim plates. 7. Remove the hinge pillar trim panels from both sides. 8. Remove the garnish molding center pillar trim. 9. Remove the carpet. Installation Procedure 1. Install the carpet. 2. Install the garnish molding center pillar trim. 3. Install the hinge pillar trim panels. 4. Install the door sill trim plates. 5. Install the lower bracket from the IP to the floor. 6. Install the floor center console, if equipped. 7. Install the front center seats, if equipped. 8. Install the rear seats. 9. Install the front seats. Carpet Replacement - Rear Carpet Replacement - Rear Removal Procedure 1. Remove the rear seat. 2. Remove the second rear seat, if equipped. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 13389 3. Remove the rear door sill trim plates. 4. Remove the endgate or the liftgate door sill trim plate. 5. Remove the trim panels for the rear quarter. 6. Remove the bolts that retain the cargo tie down hooks to the floor. 7. Remove the cargo tie down hooks. 8. Remove the rear carpet from the vehicle. Installation Procedure 1. Install the rear carpet to the vehicle. 2. Install the cargo tie down hooks. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 13390 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts that retain the cargo tie down hooks to the floor. Tighten the bolts to 35 N.m (26 lb ft). 4. Install the endgate or the liftgate door sill trim plate. 5. Install the trim panels for the rear quarter. 6. Install the door sill trim plates. 7. Install the second rear seat if equipped. 8. Install the rear seat. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions Console Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13396 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13397 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13398 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13399 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13400 Console Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13401 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13402 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13403 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13404 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13405 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13406 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13407 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13408 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13409 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13410 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13411 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13412 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13413 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13414 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13415 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13416 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13417 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13418 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13419 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13420 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13421 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13422 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13423 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13424 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 13425 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Page 13426 Console Lamp: Service and Repair REMOVAL PROCEDURE IMPORTANT: Do not disconnect the electrical connectors. 1. Remove and move the console end panel rearwards. 2. Press on the tabs (1) in order to remove the lamp assembly from the end panel. 3. Disconnect the electrical connector. 4. To replace the bulb, turn counter clockwise to remove. INSTALLATION PROCEDURE 1. Install the bulb by turning clockwise. 2. Connect the electrical connector to the lamp. 3. Push in the lamp assembly until the tabs (1) are fully seated. 4. Install the console end panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lock Cylinder > Component Information > Technical Service Bulletins > Interior - Console Lock Cylinder and Key Replacement Console Lock Cylinder: Technical Service Bulletins Interior - Console Lock Cylinder and Key Replacement Bulletin No.: 01-08-49-017A Date: August 13, 2007 INFORMATION Subject: Center Front Floor Console Compartment Lock Cylinder and Key Replacement Models: 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1999-2006 Chevrolet Silverado 2000-2002 Chevrolet Suburban, Tahoe 2007 Chevrolet Silverado Classic 1999-2000 GMC Denali 1999-2006 GMC Sierra 2000-2002 GMC Yukon, Yukon XL 2001-2002 GMC Yukon Denali, Yukon Denali XL 2007 GMC Sierra Classic Supercede: This bulletin is being revised to add additional model years, revise the pricing information and provide contact information for a new lock cylinder supplier. Please discard Corporate Bulletin Number 01-08-49-017 (Section 08 - Body and Accessories). All pricing information listed in this bulletin is in U.S. dollars and is subject to change without notice. Currently there are different methods for obtaining replacement lock cylinders and keys used in the center front floor console compartment on the above vehicles. If a replacement lock cylinder and/or keys are required, follow the appropriate procedure listed for that vehicle. 1999-2007 Chevrolet Silverado (Classic) 2000-2002 Chevrolet Suburban, Tahoe 1999-2007 GMC Sierra (Classic) 2000-2002 GMC Yukon, Yukon XL The lock cylinder used in the center front floor console compartment on these vehicles is sonically welded to the inside of the console cover/lid and as a result cannot be serviced by itself. If a replacement lock cylinder is needed, it will be necessary to order a replacement console cover assembly from GMSPO. The new cover assembly comes complete with a new coded lock cylinder and two new coded keys. See Group 16.650 of the appropriate GMSPO Parts Catalog for part number information. Also on these vehicles, if the customer has lost or damaged their console keys and the lock cylinder is okay, replacement keys can be obtained directly from A-1 Manufacturing. To order replacement keys, dealers should call A-1 at 1-877-725-2121, extension 16, and supply them with the three-digit code from the lock cylinder. In addition, dealers may E-mail A-1 at [email protected] or [email protected]. If contacted by 12 noon Eastern Standard Time (EST, A-1 will cut 2 keys to the code supplied and ship UPS with the following charges (shipping included): 1 day delivery -$31.70 2 day delivery - $27.00 3 day delivery - $23.40 In addition, dealers can order a set of 174 master keys (2 keys cut to each of the 174 codes). Each 2-key set comes in a labeled poly zippered bag. In addition to the 348 master keys (174 master keys X 2), 50 blank keys will also be included in poly bags for dealers to cut from the masters using a profile key cutter. Master keys and blanks will be shipped via UPS Ground with the following charges (including shipping): One set of 174 master keys (348 keys) and 50 blanks in poly bags - $254.10 Additional 50 blank keys in poly bags - $42.75 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1999-2000 GMC Yukon Denali Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lock Cylinder > Component Information > Technical Service Bulletins > Interior - Console Lock Cylinder and Key Replacement > Page 13431 2001-2002 GMC Yukon Denali and Yukon Denali XL On these vehicles, if a replacement lock cylinder is needed, it can be ordered from GMSPO. The replacement lock cylinder comes already coded with two keys. See Group 16.650 of the appropriate GMSPO Parts Catalog for part number information. If only replacement keys are needed, they can be obtained directly from A-1 Security Mfg. Corporation. See the ordering information listed above. Additional Information Additional replacement lock cylinders (random codes) can also be ordered directly from A-1 in quantities of 10. Each comes complete with 2 keys on a ring and packaged in a poly bag. Listed below is the cost of 10 replacement lock cylinders and keys including shipping: 1 day delivery - $66.63 ' 2 day delivery - $49.28 3 day delivery - $44.97 UPS Ground - $37.29 Blank keys can also be ordered directly from A-1 in quantities of 10. The blanks come in a poly bag and can be used with a profile key cutter to duplicate an existing key. The cost of 10 blanks is $15.40, which includes UPS Ground shipping. Ordering When ordering from A-1, please provide your dealership name, location, and dealer code for identification and if applicable, the 3-digit code from the customer's lock cylinder or key. Additional Shipping Charges Add an additional charge of $10.00 to the above quoted prices when shipping to Alaska, Hawaii, Canada and Puerto Rico. Add an additional $20.00 to the above quoted prices when shipping to remote locations in Alaska, Hawaii and Canada. Payment Terms A credit card is preferred. An account can be set up upon request, payment net 30 days. References will be required. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the fuse block. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Disconnect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 7. Access the IP module yellow 2-way connector (1) located behind the IP module (2) by removing the upper IP trim panel. Refer to Trim Pad Replacement - IP Upper in Instrument Panel, Gauges and Warning Indicators. 8. Remove the CPA from the IP module yellow 2-way connector (1) located behind the IP module (2). 9. Disconnect the IP module yellow 2-way connector (1) located behind the IP module (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 13437 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the IP module yellow 2-way connector (1) located behind the main IP support. 3. Install the CPA to the IP module yellow 2-way connector (1) located behind the main IP support. 4. Connect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 5. Install the CPA (1) to the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Install the AIR BAG Fuse to the fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - SIR if the AIR BAG indicator does not operate as described. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Diagrams Cupholder Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Cupholder Replacement - Front Floor Console Drink Holders: Service and Repair Cupholder Replacement - Front Floor Console Cupholder Replacement - Front Floor Console Removal Procedure 1. Open the cup holder by pulling down from the rear of the floor console. 2. Remove the tabs (1) that connect the cupholder to the floor console by gently prying apart with a flat bladed tool. 3. Remove the cup holder from the vehicle. Installation Procedure 1. Install the cup holder to the vehicle. 2. Install the cup holder to the floor console by snapping tabs (1) to console back in place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Cupholder Replacement - Front Floor Console > Page 13443 3. Close the cup holder by pushing back up into the rear of the floor console. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Cupholder Replacement - Front Floor Console > Page 13444 Drink Holders: Service and Repair Cupholder Replacement - Front Seat Cupholder Replacement - Front Seat Removal Procedure 1. Remove the center seat. Caution: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. 2. Remove the rivets (1) retaining the cupholder from the bottom of the center seat. 3. Remove the cupholder. Installation Procedure 1. Install the cupholder. 2. Install the rivets (1) retaining the cupholder to the bottom of the center seat. 3. Install the center seat. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Cupholder Replacement - Front Floor Console > Page 13445 Drink Holders: Service and Repair Cupholder Replacement Cupholder Replacement Removal Procedure 1. Tilt the cupholder down. 2. Remove the screws holding the cupholder to the instrument panel (IP). 3. Remove the cupholder from the vehicle. Installation Procedure 1. Position the cupholder to the IP. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws holding the cupholder to the IP. Tighten the screws to 2 N.m (18 lb in). 3. Return the cupholder to the up position. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair Glove Compartment: Service and Repair Compartment Replacement - IP Removal Procedure 1. Close the IP compartment door. 2. Drill out the 2 rivets (2). 3. Remove IP storage compartment door retaining screws (1) from the instrument panel. 4. Remove the IP compartment door. Installation Procedure 1. Install the IP compartment door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the IP compartment retaining screws (1) to the instrument panel. Tighten the screws to 1.9 N.m (17 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headliner Replacement Headliner: Service and Repair Headliner Replacement Headliner Replacement Removal Procedure 1. Remove the IP top trim panel. 2. Remove the drivers side accessory housing (1) from the IP. 3. Remove the IP upper brackets. 4. Remove the transfer case control module, if equipped. 5. Release the pressure on the headliner wire harness by removing the wire harness retainer (1) from the IP support beam. 6. Disconnect the headliner wire connectors from the junction block located next to the brake pedal. 7. Remove the wire harness retainers along the windshield pillar. 8. Follow the routing of the wire harness through the IP and release any wire harness retainers. 9. Carefully pull out the wire harness from the windshield pillar ensuring that the wire harness does not get caught on any part. 10. Remove the center trim pillar moldings. 11. Remove the third pillar trim pillar moldings. 12. Remove the rear corner trim pillar moldings. 13. Disconnect the electrical connector to the rear view mirror. 14. Remove the upper console. 15. Remove the front sunshades. 16. Remove the sunshade holders. 17. Remove the rear coat hook, if equipped. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headliner Replacement > Page 13453 18. Remove the assist handles. 19. Remove auxiliary climate control console assembly. 20. Remove the roof mounted air outlet louver by turning counter clockwise in order to remove the retainer. 21. Remove the retainer. 22. Remove the sunroof finishing lace, if equipped. 23. Remove the rear headliner retainers, if needed. 24. Carefully separate the air duct at the right C-pillar from the headliner. 25. Carefully separate the headliner from the roof Velcro(R) retainers. 26. With the aid of an assistant carefully slide the headliner out through the rear of the vehicle. 27. Remove the interior dome lamp assembly in order to transfer to the new headliner. Installation Procedure 1. Install the interior dome lamp assembly to the new headliner. 2. With the aid of an assistant carefully slide the headliner in through the rear of the vehicle. 3. Secure the headliner to the roof Velcro(R) retainers while aligning the air duct at the right of the third pillar. 4. Install the retainer through the air outlet louver 5. Install the air outlet louver by turning clockwise till it is seated in place. 6. Install the auxiliary climate control assembly. 7. Install the assist handles. 8. Install the interior dome lamp. 9. Install the rear coat hook, if equipped. 10. Install the sunshade holders to the headliner. 11. Install the front sunshades. 12. Connect the electrical connector to the rear view mirror, if needed. 13. Install the upper console. 14. Install the rear corner trim pillar moldings. 15. Install the third pillar trim moldings. 16. Install the center trim pillar moldings. 17. Carefully route the wire harness through the IP in order to connect the wire to the junction block located next the brake pedal. 18. Install the transfer case control module, if equipped. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headliner Replacement > Page 13454 Important: Please ensure that all of the wire harness retainers in the IP and the windshield pillar are all pressed into place in order to prevent rattling during driving. 19. Press in the wire harness retainer (1) in order to secure the harness. 20. Connect the headliner electrical connectors to the junction block located next to the brake pedal. 21. Install the drivers side accessory housing (1) to the IP. 22. Install the sunroof finishing lace, if equipped. 23. Install the IP top trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headliner Replacement > Page 13455 Headliner: Service and Repair Headliner Replacement - Rear Headliner Replacement - Rear Removal Procedure Important: Do not disconnect the headliner wire harness from the junction block. 1. Lower the front section of the headliner and suitably support. Refer to Headliner Replacement. 2. Disconnect the electrical connector. 3. Remove the rear corner moldings. 4. Remove the rear upper trim molding. 5. Remove the rear coat hook. 6. Carefully release the headliner from the roof support Velcro(R) retainers. 7. Remove the headliner from the vehicle. Installation Procedure 1. Install the rear section of the headliner to the vehicle. 2. Secure the headliner to the roof support Velcro(R) retainers. 3. Connect the electrical connector. 4. Install the rear coat hook. 5. Install the rear upper trim molding. 6. Install the rear corner molding. 7. Install the front section of the headliner. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Assist Handle Replacement (Front) Passenger Assist Handle: Service and Repair Assist Handle Replacement (Front) Assist Handle Replacement - Front Removal Procedure 1. Lower the right side of the headliner. Refer to Headliner Replacement. 2. Turn the retainers in the directions as shown in the graphic and then remove the retainers. 3. Remove the assist handle from the headliner. Installation Procedure 1. Install the assist handle through the opening in the headliner. 2. While holding the assist handle to the head liner install the retainer in the direction as shown in the graphic. 3. Install the headliner. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Assist Handle Replacement (Front) > Page 13460 Passenger Assist Handle: Service and Repair Assist Handle Replacement (Rear) Assist Handle Replacement - Rear Removal Procedure 1. Remove center pillar trim panel. 2. Remove the assist handle retraining screws. 3. Remove the assist handle from the vehicle. Installation Procedure 1. Install the assist handle to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the assist handle screws. Tighten the screws to 6 N.m (53 lb in). 3. Install the center pillar trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Assist Handle Replacement (Front) > Page 13461 Passenger Assist Handle: Service and Repair Instrument Panel (I/P) Assist Handle Replacement IP Assist Handle Replacement Removal Procedure 1. Remove both the passenger side air deflector louvers. 2. Press the release tabs on the instrument panel assist handle retainers on both sides. 3. Pull the assist handle from the instrument panel. Installation Procedure 1. Install the instrument panel assist handle by pushing till it locks into place. 2. Install both the passenger side air deflector louvers. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Door Sill Plate Replacement - Front Scuff Plate: Service and Repair Door Sill Plate Replacement - Front Door Sill Plate Replacement - Front Removal Procedure 1. Remove the sill plate. Firmly pull the sill plate up and out from the retainers. 2. Remove the sill plate from the vehicle. Start from the front of the door sill. Use a flat-bladed tool in order to pry the door sill plate. Installation Procedure 1. Install the sill plate. 2. Push the sill plate down until the sill plate locks into place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Door Sill Plate Replacement - Front > Page 13466 Scuff Plate: Service and Repair Door Sill Plate Replacement - Lift Gate Door Sill Plate Replacement - Lift Gate Removal Procedure Use a flat-bladed tool in order to remove the door sill trim plate from the vehicle. Installation Procedure Install the door sill trim plate to the vehicle. Align the retainers along the door sill and press into place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Door Sill Plate Replacement - Front > Page 13467 Scuff Plate: Service and Repair Door Sill Plate Replacement - Rear Door Sill Plate Replacement - Rear Removal Procedure 1. Use a flat-bladed tool in order to pry the door sill plate. 2. Remove the sill plate from the vehicle. Installation Procedure 1. Install the sill plate. 2. Push the sill plate down until the sill plate locks into place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Customer Interest for Sun Visor: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Sun Visor: Customer Interest Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Bulletin No.: 06-08-42-002A Date: January 23, 2007 TECHNICAL Subject: Sunshade (Visor) Vanity Mirror Bulb Inoperative (Replace Vanity Mirror Bulb Only) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2005-2007 Cadillac STS 2001-2005 Chevrolet Impala, Monte Carlo 2001-2006 Chevrolet Silverado Crew Cab, Suburban, Tahoe 2001-2006 GMC Sierra Crew Cab, Yukon, Yukon XL 2004-2005 Pontiac Grand Prix 2006-2007 HUMMER H3 Supercede: This bulletin is being updated to add the 2007 model year. Please discard Corporate Bulletin Number 06-08-42-002 (Section 08 - Body & Accessories). Condition Some customers may comment that a sunshade (visor) vanity mirror bulb is inoperative. Cause This condition may be caused by an inoperative bulb. Correction Do NOT replace the entire sunshade (visor) assembly. Replace the sunshade (visor) vanity mirror bulb with P/N 9442395 if repairing one of the affected models covered for an inoperative vanity mirror bulb. Refer to Vanity Mirror Lamp Replacement in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Customer Interest for Sun Visor: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. > Page 13476 The vanity mirror bulb can be accessed by removing the lens. Place a flat-bladed tool in the notches and gently pry out the lens. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Visor: > 06-08-42-002A > Jan > 07 > Interior Lighting Sun Visor Vanity Mirror Lamp Inop. Sun Visor: All Technical Service Bulletins Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Bulletin No.: 06-08-42-002A Date: January 23, 2007 TECHNICAL Subject: Sunshade (Visor) Vanity Mirror Bulb Inoperative (Replace Vanity Mirror Bulb Only) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2005-2007 Cadillac STS 2001-2005 Chevrolet Impala, Monte Carlo 2001-2006 Chevrolet Silverado Crew Cab, Suburban, Tahoe 2001-2006 GMC Sierra Crew Cab, Yukon, Yukon XL 2004-2005 Pontiac Grand Prix 2006-2007 HUMMER H3 Supercede: This bulletin is being updated to add the 2007 model year. Please discard Corporate Bulletin Number 06-08-42-002 (Section 08 - Body & Accessories). Condition Some customers may comment that a sunshade (visor) vanity mirror bulb is inoperative. Cause This condition may be caused by an inoperative bulb. Correction Do NOT replace the entire sunshade (visor) assembly. Replace the sunshade (visor) vanity mirror bulb with P/N 9442395 if repairing one of the affected models covered for an inoperative vanity mirror bulb. Refer to Vanity Mirror Lamp Replacement in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Visor: > 06-08-42-002A > Jan > 07 > Interior Lighting Sun Visor Vanity Mirror Lamp Inop. > Page 13482 The vanity mirror bulb can be accessed by removing the lens. Place a flat-bladed tool in the notches and gently pry out the lens. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Page 13483 Sun Visor: Service and Repair Sunshade Replacement Removal Procedure 1. Remove the screws. 2. Disconnect the electrical connector, if equipped. 3. Remove the sunshade. Installation Procedure 1. Connect the electrical connector, if equipped. 2. Install the sunshade. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the sunshade screws. Tighten the screw to 2 N.m (18 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement Trim Panel: Service and Repair Garnish Molding Replacement Garnish Molding Replacement - Lift Gate REMOVAL PROCEDURE 1. Open the liftgate window. 2. Remove the push pin retainers from the garnish molding. 3. Pry gently with a thin-bladed tool in order to release the retaining clips. 4. Remove the garnish molding. INSTALLATION PROCEDURE 1. Install the garnish molding to the door. 2. Press on the garnish molding in order to engage the retaining clips. 3. Install the push pin retainers into the garnish molding. 4. Close the liftgate window. Garnish Molding Replacement - Rear Door Frame REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 13488 1. Open the rear door. 2. Pry gently with a thin bladed tool in order to remove the retaining clips. 3. Remove the garnish molding from the door. INSTALLATION PROCEDURE 1. Install the garnish molding to the door. 2. Press on the garnish molding in order to install the retaining clips. 3. Close the rear door. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 13489 Trim Panel: Service and Repair Garnish Molding Replacement - Center Pillar Garnish Molding Replacement - Center Pillar Removal Procedure 1. Remove the door sill plates. 2. Remove the pillar moldings by holding the moldings firmly while pulling out. Installation Procedure 1. Install the pillar moldings by pushing until the molding locks into place. 2. Install the door sill trim plates. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 13490 Trim Panel: Service and Repair Garnish Molding Replacement - Lift Gate Garnish Molding Replacement - Lift Gate Removal Procedure 1. Open the liftgate window. 2. Remove the push pin retainers from the garnish molding. 3. Pry gently with a thin-bladed tool in order to release the retaining clips. 4. Remove the garnish molding. Installation Procedure 1. Install the garnish molding to the door. 2. Press on the garnish molding in order to engage the retaining clips. 3. Install the push pin retainers into the garnish molding. 4. Close the liftgate window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 13491 Trim Panel: Service and Repair Garnish Molding Replacement - Rear Corner Garnish Molding Replacement - Rear Corner Removal Procedure 1. Remove the rear upper garnish molding. 2. Pull down on the upper corners of the garnish molding in order to disengage the retaining clips. 3. Pull in order to disengage the remaining retaining clips. 4. Remove the rear corner garnish molding from the vehicle. 5. Inspect the rear corner garnish molding for broken or missing retaining clips. Replace the retaining clips as needed. Installation Procedure 1. Install the rear corner garnish molding to the vehicle. 2. Press on the rear corner garnish molding in order to engage the retaining clips. 3. Install the rear upper garnish molding. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 13492 Trim Panel: Service and Repair Garnish Molding Replacement - Lift Gate REMOVAL PROCEDURE 1. Open the liftgate window. 2. Remove the push pin retainers from the garnish molding. 3. Pry gently with a thin-bladed tool in order to release the retaining clips. 4. Remove the garnish molding. INSTALLATION PROCEDURE 1. Install the garnish molding to the door. 2. Press on the garnish molding in order to engage the retaining clips. 3. Install the push pin retainers into the garnish molding. 4. Close the liftgate window. Garnish Molding Replacement - Rear Door Frame REMOVAL PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 13493 1. Open the rear door. 2. Pry gently with a thin bladed tool in order to remove the retaining clips. 3. Remove the garnish molding from the door. INSTALLATION PROCEDURE 1. Install the garnish molding to the door. 2. Press on the garnish molding in order to install the retaining clips. 3. Close the rear door. Garnish Molding Replacement - Center Pillar Garnish Molding Replacement - Center Pillar Removal Procedure 1. Remove the door sill plates. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 13494 2. Remove the pillar moldings by holding the moldings firmly while pulling out. Installation Procedure 1. Install the pillar moldings by pushing until the molding locks into place. 2. Install the door sill trim plates. Garnish Molding Replacement - Lift Gate Garnish Molding Replacement - Lift Gate Removal Procedure 1. Open the liftgate window. 2. Remove the push pin retainers from the garnish molding. 3. Pry gently with a thin-bladed tool in order to release the retaining clips. 4. Remove the garnish molding. Installation Procedure 1. Install the garnish molding to the door. 2. Press on the garnish molding in order to engage the retaining clips. 3. Install the push pin retainers into the garnish molding. 4. Close the liftgate window. Garnish Molding Replacement - Rear Corner Garnish Molding Replacement - Rear Corner Removal Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 13495 1. Remove the rear upper garnish molding. 2. Pull down on the upper corners of the garnish molding in order to disengage the retaining clips. 3. Pull in order to disengage the remaining retaining clips. 4. Remove the rear corner garnish molding from the vehicle. 5. Inspect the rear corner garnish molding for broken or missing retaining clips. Replace the retaining clips as needed. Installation Procedure 1. Install the rear corner garnish molding to the vehicle. 2. Press on the rear corner garnish molding in order to engage the retaining clips. 3. Install the rear upper garnish molding. Garnish Molding Replacement - Rear Door Upper Garnish Molding Replacement - Rear Door Upper Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove expanding plastic fasteners at window latch close-out. 2. Using the J 38778, release the retainers from the retainer seats. 3. Remove the trim panel from the liftgate. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 13496 1. Align the retainers with the holes in the liftgate. 2. Apply pressure to the seat retainers. 3. Install the expanding plastic retainers at the window latch close-out. Garnish Molding Replacement - Rear Upper (Tahoe / Yukon / Escalade / Suburban) Garnish Molding Replacement - Rear Upper (Tahoe / Yukon / Escalade / Suburban) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Use the J 38778 in order to remove the rear upper garnish molding. Insert the J 38778 and work along the front edge of the trim panel from one end to the other. 2. Remove the rear upper garnish molding from the vehicle. Installation Procedure Install the roof rear upper garnish molding to the vehicle until it clicks into place. Garnish Molding Replacement - Windshield Pillar Garnish Molding Replacement - Windshield Pillar Removal Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 13497 1. Pull the molding straight out in order to release the retainers. 2. Remove the windshield garnish molding. Installation Procedure 1. Ensure the bottom of the molding is seated in the slots on the I/P. 2. Align the molding retainers to the slots. 3. Press the moldings straight in till fully seated. Panel Replacement - Cargo Box Bridge Center (Avalanche) Panel Replacement - Cargo Box Bridge Center (Avalanche) Removal Procedure 1. Ensure that the headlamp switch is in the OFF position. 2. Remove the rear compartment cover assembly. 3. Remove the cargo box bridge center screws (1,2). 4. Disconnect the electrical connector. 5. Remove the panel assembly from the vehicle. 6. Remove the high mount stop lamp from the cargo bridge center. Installation Procedure 1. Install the high mounted stop lamp to the cargo box bridge center. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 13498 2. Connect the electrical connector. 3. Install the panel assembly to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the panel assembly screws (1,2). Tighten the panel assembly screws (1,2) to 7 N.m (62 lb in). 5. Inspect the operation. 6. Install the rear compartment cover assembly. Panel Replacement - Removable Rear - Mid Gate REMOVAL PROCEDURE 1. Fold the rear seat back down. 2. Remove the hinges. 3. Open the midgate while leaving the back glass in place. 4. Remove the panel from the vehicle INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 13499 1. Install the panel to the vehicle 2. Install the Hinges to the panel. 3. Check the operation of the mid gate by opening and closing the mid gate. Align the mid gate if necessary. 4. Fold the rear seat back up. Trim Panel Replacement - Front Seat REMOVAL PROCEDURE 1. Ensure the seat is in the full upward position. 2. Remove the screws retaining the seat back release handle and the seat recliner handle and remove the handles. 3. Remove the remaining screws retaining the trim panel to the seat. 4. Remove the trim panel from the seat. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 13500 1. Position the trim panel on the seat. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws retaining the trim panel to the seat. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the remaining screws retaining the seat back release handle and the seat recliner handle to the seat. Tighten Tighten the screws to 2 N.m (18 lb in). Trim Panel Replacement - Hinge Pillar Trim Panel Replacement - Hinge Pillar Removal Procedure 1. Remove door sill plate.. 2. Remove hinge pillar panel. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 13501 1. Install the hinge pillar panel. 2. Install the door sill plate. Garnish Molding Replacement - Rear Door Frame Garnish Molding Replacement - Rear Door Frame Removal Procedure 1. Open the rear door. 2. Pry gently with a thin bladed tool in order to remove the retaining clips. 3. Remove the garnish molding from the door. Installation Procedure 1. Install the garnish molding to the door. 2. Press on the garnish molding in order to install the retaining clips. 3. Close the rear door. Trim Panel Replacement - Rear Quarter - Left (Utility) Trim Panel Replacement - Rear Quarter - Left (Utility) Removal Procedure 1. Remove the rear seat. 2. Remove the Third-Pillar trim panel. 3. Remove the garnish molding. 4. Remove the door sill plate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 13502 5. Remove the quarter panel trim screws. 6. Remove the quarter panel trim from the vehicle. Installation Procedure 1. Install the quarter panel trim to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the quarter panel trim screws. Tighten the screws to 2 N.m (18 lb in). 3. Install garnish molding. 4. Install the door sill plate. 5. Install the Third-Pillar trim panel. 6. Install the rear seat. Trim Panel Replacement - Rear Quarter - Right (Utility) Trim Panel Replacement - Rear Quarter - Right (Utility) Removal Procedure 1. Remove the rear seat. 2. Remove the Third Pillar trim panel. 3. Remove the garnish molding. 4. Remove the door sill plate. 5. Remove the quarter panel trim screws. 6. Remove the quarter panel trim from the vehicle. Lift the quarter panel to release the quarter panel from the vehicle. Installation Procedure 1. Install the quarter panel trim to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 13503 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the quarter panel trim screws. Tighten the screws to 2 N.m (18 lb in). 3. Install the door sill plate. 4. Install the garnish molding. 5. Install the Third Pillar trim panel. 6. Install the rear seat. Trim Replacement - Third Pillar (Tahoe / Yukon / Escalade / Suburban) Trim Replacement - Third Pillar (Tahoe / Yukon / Escalade / Suburban) Removal Procedure 1. Remove the rear door sill trim plate. 2. Remove the lower rear seat belt cover and bolt. 3. Remove the trim panel from the vehicle. Installation Procedure 1. Install the body side lower trim panel to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the lower seat belt bolt. Tighten the bolt to 70 N.m (52 lb ft). 3. Install the seat belt cover. 4. Install the rear door sill trim plate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Box Replacement - Cargo Stowage (Avalanche) Utility Storage Compartment: Service and Repair Box Replacement - Cargo Stowage (Avalanche) Box Replacement - Cargo Stowage (Avalanche) Removal Procedure 1. Remove the rear compartment cover assembly. 2. Remove the assist handle. 3. Remove the cargo box stowage lid assembly. 4. Remove the lamp socket from the pickup box side courtesy lamp. 5. Remove the cargo tie-down bolts and tie rings from the body side inner panel. 6. Remove the cargo box stowage box from the vehicle. Installation Procedure 1. Install the cargo box stowage box to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the cargo tie-down rings and bolts to the body side inner panel. Tighten the bolts to 9 N.m (80 lb in). 3. Install the cargo box stowage lid assembly. 4. Install the lamp socket to the pickup box side courtesy lamp assembly. 5. Install the assist handle. 6. Install the rear compartment cover assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Box Replacement - Cargo Stowage (Avalanche) > Page 13508 Utility Storage Compartment: Service and Repair Lid Replacement - Cargo Box Stowage Box (Avalanche) Lid Replacement - Cargo Box Stowage Box (Avalanche) Removal Procedure 1. Lower the end gate. 2. Remove the rear compartment cover assembly. 3. Remove the assist handle. 4. Remove the cargo box bridge side inner panel. 5. Remove the bolts (2) from inside the cargo box stowage lid assembly. 6. Remove the bolts (1) from the top of the stowage lid. 7. Remove the cargo box from the vehicle. Installation Procedure 1. Install the cargo box stowage lid to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (1) to the cargo box stowage lid. Tighten the bolts to 9 N.m (80 lb in). 3. Install the bolt (2) inside the cargo box stowage lid assembly. Tighten the bolt to 9 (80 lb in). 4. Install the cargo box bridge side inner panel. 5. Install the assist handle. 6. Install the rear compartment cover assembly. 7. Close the end gate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Box Replacement - Cargo Stowage (Avalanche) > Page 13509 Utility Storage Compartment: Service and Repair Lock Cylinder Replacement - Cargo Box Stowage Box (Avalanche) Lock Cylinder Replacement - Cargo Box Stowage Box (Avalanche) Removal Procedure 1. Open the cargo box stowage lid. 2. Depress the spring-loaded locking tab. 3. Turn the lock cylinder 1/4 turn clockwise. 4. Remove the cargo lock cylinder assembly from the stowage lid. Installation Procedure 1. Install the lock cylinder assembly to the cargo box stowage lid. 2. Turn the lock cylinder 1/4 turn counterclockwise in order to lock. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Binding Lock Cylinders Door Lock Cylinder: Service and Repair Binding Lock Cylinders In many cases, applying the proper lubrication can correct the following conditions: ^ Binding or sticking door lock cylinders ^ Difficulty in inserting and removing the keys For lubricating the above components, use lubricant GM P/N 12346241 or equivalent Do not use penetrating lubricants such as GM P/N 1052949 or WD-40(R). Penetrating lubricants wash out the original lubrication. Penetrating lubricants eventually evaporate, leaving little or no lubricating material. However, when using penetrating lubricants in order to thaw or in order to loosen the lock cylinder components, refer to steps 2-4 in the procedure below for the proper methods of lubrication. Repair lock cylinders frozen in cold weather by using the following procedure: 1. While carefully avoiding damage to the painted surfaces, apply heat to the cylinder with a heat gun. 2. Using a paper clip or a similar item, hold the door shutter open. Force air into the cylinders using compressed air through a blow gun attachment. 3. While holding the shutter door open, inject small amounts of a recommended lubricant into the cylinder. 4. Work the key into the cylinder repeatedly. Wipe away any excess lubrication from the key. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Binding Lock Cylinders > Page 13516 Door Lock Cylinder: Service and Repair Door Lock Cylinder Replacement Lock Cylinder Replacement - Door Removal Procedure 1. Raise the window completely. 2. Remove the front door trim panel. 3. Remove the water deflector. 4. Remove the outside door handle. 5. Remove the clip that retains the lock cylinder lever to the lock cylinder. 6. Remove the lock cylinder retainer. Installation Procedure 1. Install the lock cylinder into the outside door handle. 2. Install the clip. 3. Install the outside door handle. 4. Install the front door water deflector. 5. Install the front door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Knob > Component Information > Technical Service Bulletins > Customer Interest: > 01-08-64-014A > Jul > 02 > Interior - Lock Lever Comes Loose From Door Trim Panel Door Lock Knob: Customer Interest Interior - Lock Lever Comes Loose From Door Trim Panel File In Section: 08 - Body and Accessories Bulletin No.: 01-08-64-014A Date: July, 2002 TECHNICAL Subject: Door Manual Lock Lever Disengages from Door Trim Panel (Replace Lock Lever) Models: 2002 Cadillac Escalade 1999-2003 Chevrolet Silverado 2000-2003 Chevrolet Suburban, Tahoe 2002-2003 Chevrolet Avalanche 1999-2003 GMC Sierra 2000-2003 GMC Yukon, Yukon XL 2001-2003 GMC Denali This bulletin is being revised to add a model year and parts information and to change the Correction and Warranty Information. Please discard Corporate Bulletin Number 01-08-64-014 (Section 08 - Body and Accessories). Condition Some customers may comment that the manual lock lever comes loose from the door trim panel. Cause The manual lock lever may not have been seated all the way and has caused the retaining barb to deform. Refer to arrow in the illustration above. Correction Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Knob > Component Information > Technical Service Bulletins > Customer Interest: > 01-08-64-014A > Jul > 02 > Interior - Lock Lever Comes Loose From Door Trim Panel > Page 13525 Replace the manual lock lever with P/N 15172121. The new lock lever has a revised retaining barb. Refer to the illustration above. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Knob > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-08-64-014A > Jul > 02 > Interior - Lock Lever Comes Loose From Door Trim Panel Door Lock Knob: All Technical Service Bulletins Interior - Lock Lever Comes Loose From Door Trim Panel File In Section: 08 - Body and Accessories Bulletin No.: 01-08-64-014A Date: July, 2002 TECHNICAL Subject: Door Manual Lock Lever Disengages from Door Trim Panel (Replace Lock Lever) Models: 2002 Cadillac Escalade 1999-2003 Chevrolet Silverado 2000-2003 Chevrolet Suburban, Tahoe 2002-2003 Chevrolet Avalanche 1999-2003 GMC Sierra 2000-2003 GMC Yukon, Yukon XL 2001-2003 GMC Denali This bulletin is being revised to add a model year and parts information and to change the Correction and Warranty Information. Please discard Corporate Bulletin Number 01-08-64-014 (Section 08 - Body and Accessories). Condition Some customers may comment that the manual lock lever comes loose from the door trim panel. Cause The manual lock lever may not have been seated all the way and has caused the retaining barb to deform. Refer to arrow in the illustration above. Correction Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Knob > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-08-64-014A > Jul > 02 > Interior - Lock Lever Comes Loose From Door Trim Panel > Page 13531 Replace the manual lock lever with P/N 15172121. The new lock lever has a revised retaining barb. Refer to the illustration above. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Knob > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Knob: > 02-05-22-004C > Apr > 05 > Electrical Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Knob > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Knob: > 02-05-22-004C > Apr > 05 > Electrical Trailer Brakes Apply With Headlamps ON > Page 13537 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Knob > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Knob: > 02-05-22-004C > Apr > 05 > Electrical Trailer Brakes Apply With Headlamps ON > Page 13538 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Knob > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Knob: > 02-05-22-004C > Apr > 05 > Electrical Trailer Brakes Apply With Headlamps ON > Page 13544 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Knob > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Knob: > 02-05-22-004C > Apr > 05 > Electrical Trailer Brakes Apply With Headlamps ON > Page 13545 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 13550 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 13551 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 13552 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 13557 Remote Control Door Lock Receiver (RCDLR) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 13558 Keyless Entry Receiver: Service and Repair REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel (IP) top cover. 2. Remove the module. Unsnap the 2 look arms. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the module starting with the large tang-tilt. Snap the 2 lock arms into the square holes. 3. Install the instrument panel (IP) top cover. 4. Program the transmitter. See: Testing and Inspection/Programming and Relearning Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE Under normal use, the battery in the transmitter will last about 2 years. For battery replacement, use a Panasonic 3 volt, type CR2032, or equivalent. 1. Open the transmitter case and perform the following steps: 1.1. Insert a dime between the 2 halves of the transmitter near the key ring hole. 1.2. Twist the dime. 2. Remove the battery. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair > Page 13563 1. Install the battery with the (+) positive side down. 2. Close the transmitter case and perform the following steps: 2.1. Align the top and bottom covers. 2.2. Press together the top and the bottom covers. 2.3. Inspect the operation of the transmitter. 3. Synchronize the transmitter. Refer to Transmitter Synchronization. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams Power Door Lock Actuator: Diagrams Door Lock Actuator - Cargo/Liftgate Door Lock Actuator - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 13568 Door Lock Actuator - Front Passenger/RR/LR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Lock Actuator Replacement - Front Door Power Door Lock Actuator: Service and Repair Lock Actuator Replacement - Front Door Lock Actuator Replacement - Front Door Removal Procedure 1. Raise the window glass. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Disconnect the inside door lock rod from the handle retainer clip. 5. Disconnect the manual door lock rod from the door retainer clips. 6. Remove the rubber plug (1) in order to disengage the outside handle rod retainer. 7. Disconnect the cylinder lock rod (1). 8. Remove the bolts (2) which retain the door lock actuator to the door. 9. Remove the door lock actuator and the control rods as an assembly. 10. Disconnect the electrical connector from the door lock actuator, if equipped. 11. Remove the control rods as necessary. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Lock Actuator Replacement - Front Door > Page 13571 1. Install the control rods to the assembly. 2. Connect the electrical connectors to the door lock actuator, if equipped 3. Install the door lock actuator to the door. 4. Connect the control rod to the outside door handle. 5. Connect the cylinder lock rod. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bolts that retain the door lock actuator to the door. Tighten the screws to 9 N.m (80 lb in). 7. Connect the manual door lock to the door retainer clips. 8. Connect the control rod for the inside door handle to the lock assembly (1). 9. Connect the inside door lock rod to the handle retainer clip. 10. Install the water deflector. 11. Install the door trim panel. 12. Inspect the operation of all the related components. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Lock Actuator Replacement - Front Door > Page 13572 Power Door Lock Actuator: Service and Repair Lock Actuator Replacement - Rear Door Lock Actuator Replacement - Rear Door Removal Procedure 1. Raise the window. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Disconnect the inside door lock rod from the handle retainer clip. 5. Disconnect the manual door lock rod from the door retainer clips. 6. Remove the rubber plug in order to disengage the outside handle rod retainer. 7. Disconnect the cylinder lock rod (1). 8. Remove the bolts (2) which retain the door lock actuator to the door. 9. Remove the door lock actuator and control rods as an assembly. 10. Disconnect the electrical connector from the door lock actuator, if equipped. 11. Remove the control rods as necessary. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Lock Actuator Replacement - Front Door > Page 13573 1. Install the control rods to the assembly. 2. Connect the electrical connectors to the door lock actuator, if equipped. 3. Install the door lock actuator to the door. 4. Connect the outside door handle control rod. 5. Connect the cylinder lock rod. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bolts which retain the door lock actuator to the door. Tighten the screws to 9 N.m (80 lb in). 7. Connect the manual door lock to the door retainer clips. 8. Connect the inside door handle control rod to the lock assembly. 9. Connect the inside door lock rod to the handle retainer clip. 10. Install the water deflector. 11. Install the door trim panel. 12. Inspect the operation of all the related components. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch - Driver/Front Passenger Door Lock Switch - Driver/Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch - Driver/Front Passenger > Page 13578 Window/Door Lock Switch - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Power Door Lock Switch Replacement - Front Power Door Lock Switch: Service and Repair Power Door Lock Switch Replacement - Front REMOVAL PROCEDURE 1. Remove the power accessory switch panel. 2. Disconnect the electrical connector from the door lock switch. 3. Remove the screws from the door lock switch. 4. Remove the power window and door lock switch from the switch panel. INSTALLATION PROCEDURE 1. Install the power door lock and power window switch assembly to the switch panel, sliding the front tabs in first. Rock the switch down in order to seat the door lock switch completely. 2. Install the screws to the door lock switch. 3. Connect the electrical connector to the door lock switch. 4. Install the power accessory switch plate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Power Door Lock Switch Replacement - Front > Page 13581 Power Door Lock Switch: Service and Repair Power Door Lock Switch Replacement - Rear REMOVAL PROCEDURE 1. Remove the upper garnish molding. 2. Remove the D-Pillar molding. 3. Disconnect the electrical connectors. 4. Push on the tab (2) in order to remove the switch from the D-Pillar molding. 5. Insert a small screwdriver between the tab (1) in order to pry out the switch from the case. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Power Door Lock Switch Replacement - Front > Page 13582 1. Install the switch into the case by pushing until the tab (1) locks into place. 2. Install the switch assembly into the D-Pillar molding. 3. Connect the electrical connectors. 4. Install the D-Pillar molding to vehicle. 5. Install the upper garnish molding to vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Replacement - Lift Gate Removal Procedure 1. Remove the trim panel. 2. Remove the liftgate window latch assembly. 3. Depress the locking pin on the lock cylinder. 4. Turn lock cylinder counterclockwise. 5. Remove the liftgate lock cylinder from the latch assembly. Installation Procedure 1. Install the liftgate lock cylinder to the latch assembly. 2. Rotate lock cylinder clockwise until the pin engages. 3. Install the trim panel. 4. Install the liftgate window latch assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams Power Mirror Control Module: Diagrams Memory Mirror Module Connector C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Page 13594 Memory Mirror Module Connector C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Service and Repair > Procedures Power Mirror Control Module: Procedures The mirror relearn procedure, when initiated, commands the Memory Mirror Module (MMM) to control the driver and then the passenger mirror in the left, right, up and down directions. When commanding the mirrors the MMM also learns the direction of horizontal and vertical position sensor signal circuit feedback voltages. To initiate the relearn procedure, perform the following: 1. With a scan tool, select Memory Mirror Module 2. Select Special Functions 3. Select Output Controls 4. Select Mirror Relearn 5. Then press the Reset button If the mirror relearn procedure does not control the driver and passenger mirrors as described, there may be another fault in the mirror systems. Refer to Diagnostic System Check - Door Systems to begin the diagnosis of the mirror system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Service and Repair > Procedures > Page 13597 Power Mirror Control Module: Removal and Replacement REMOVAL PROCEDURE 1. Remove the drivers side door panel. 2. Remove the screws (1) that retain the accessory and outside rear view mirror module from the door panel. 3. Remove the nut (2) that retains the accessory and outside rear view mirror module from the door panel. 4. Remove the module from the door panel. INSTALLATION PROCEDURE 1. Install the module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nut (2) that retains the accessory and outside rear view mirror module to the door panel. Tighten Tighten the module retaining nut to 0.6 N.m (5 lb in). 3. Install the screws (1) that retain the accessory and outside rear view mirror module to the door panel. Tighten Tighten the module retaining screws to 0.6 N.m (5 lb in). 4. Install the drivers door panel. 5. Perform the memory mirror module learn procedure. Refer to Memory Mirror Module (MMM) Learn Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch Replacement Power Mirror Switch: Service and Repair Power Mirror Switch Replacement REMOVAL PROCEDURE 1. Remove the power accessory switch panel. 2. Remove the power mirror switch from the accessory switch panel using a flat-bladed tool in order to release the retainer tabs. INSTALLATION PROCEDURE 1. Install the power mirror switch, pressing the switch into place until fully seated. 2. Install the power accessory switch panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch Replacement > Page 13602 Power Mirror Switch: Service and Repair Power Folding Outside Mirror Switch Replacement REMOVAL PROCEDURE 1. Remove the instrument panel (IP) bezel. 2. Release the plastic retaining clips using a flat-bladed tool in order to remove the power folding mirror switch. 3. Disconnect the electrical connectors. 4. Remove the power folding mirror switch from the IP accessory housing. INSTALLATION PROCEDURE 1. Connect the electrical connectors. 2. Install the power folding mirror switch to the IP accessory housing. 3. Push in the power folding mirror switch until the switch snaps into position. 4. Install the power accessory switch panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 13612 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 13618 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 13628 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 13629 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 13630 TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 13631 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Technician Safety Information Paint: Technician Safety Information Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Technician Safety Information > Page 13634 Paint: Vehicle Damage Warnings Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code Charts Paint: Application and ID Paint Code Charts Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code Charts > Page 13637 Paint: Application and ID Paint Identification Precautions PAINT IDENTIFICATION Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM PIN 4901 MD This book identities the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: 1. A cathodic immersion primer 2. A primer/surfacer 3. A basecoat 4. A clear top coat (clearcoat) Refer to the Service Parts ID Label to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code Charts > Page 13638 Paint: Application and ID Parts ID Label Location Label - Service Parts ID Label - Service Parts ID Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code Charts > Page 13639 The service parts identification label is placed on the vehicle in order to help the service and parts personnel identify the vehicle's original parts and the vehicle's original options. The label is located in the instrument panel compartment (glove box). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code Charts > Page 13640 Paint: Application and ID Paint Identification Paint Identification Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important: Always refer to the GM Approved Refinish Materials book GM P/N 4901M-D. This book identifies the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: * A cathodic immersion primer * A primer/surfacer * A basecoat * A clear top coat (clearcoat) Refer to Label - Service Parts ID in General Information in order to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Page 13641 Paint: Service and Repair Basecoat/Clearcoat Paint Systems Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Caution: Refer to Eye Protection Caution in Service Precautions. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D-99 identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers. If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clearcoat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel.) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: * Lifting of primer coats caused by overly aggressive solvents in subsequent layers * Loss of adhesion between layers due to incompatibility of resin systems * Solvent popping or pinholing due to inappropriate solvent selection * Poor through-curing due to incompatible hardener resins or insufficient reactivity * Gloss reduction due to incompatible resins and/or solvents * Poor color accuracy due to pigment interactions with incompatible resins and/or solvents * Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Description and Operation Radiator Support: Description and Operation Radiator Support Description The radiator support assembly is made of aluminum alloy. You can repair minor damage with ER-4043 welding wire and 100 percent argon shielding gas. The upper tie-bar (1) and the vertical support (2) portion of the radiator support assembly are bolt-on components. The tie-bar and the vertical support (2) are available as part of the radiator support assembly, or can be ordered separately. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Support Replacement - Radiator Grille Reinforcement Radiator Support: Service and Repair Support Replacement - Radiator Grille Reinforcement Support Replacement - Radiator Grille Reinforcement Removal Procedure 1. Remove the headlamps. 2. Remove the park/turn signal lamps. 3. Remove the grille. 4. Remove the front fascia. 5. Remove the retaining bolts (3) from the grille reinforcement. 6. Remove the retaining screws (2) from the grille reinforcement. 7. Remove the reinforcement from the vehicle. Installation Procedure 1. Install the reinforcement to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screws (2) to the grille reinforcement. Tighten the screws to 7 N.m (62 lb in). 3. Install the retaining bolts (3) to the reinforcement. Tighten the screws to 7 N.m (62 lb in). 4. Install the park/turn signal lamps. 5. Install the headlamps. 6. Install the grille. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Support Replacement - Radiator Grille Reinforcement > Page 13647 Radiator Support: Service and Repair Tie Bar Replacement - Upper Tie Bar Replacement - Upper Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the upper radiator baffle.. 3. Remove the headlamps. 4. Remove the upper condenser mounting bolts. 5. Remove the bolts from the front end diagonal brace. 6. Remove the front end diagonal brace. 7. Remove the fan shroud. 8. Remove the tie bar to radiator brace bolts (1). Access the bolts from the rear of the upper radiator support using an extension. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Support Replacement - Radiator Grille Reinforcement > Page 13648 9. Remove the radiator mounting bolts from the rear side of the tie bar. 10. Remove the tie bar bolts. 11. Remove the upper headlamp housing support screws. 12. Remove the tie bar. Installation Procedure 1. Position the tie bar onto the lower radiator support. 2. Install the tie bar bolts hand tight. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Support Replacement - Radiator Grille Reinforcement > Page 13649 Important: Ensure that the alignment is proper. 3. Tighten the tie bar bolts. Tighten the tie bar bolts to 9 N.m (80 lb in). 4. Install the upper headlamp housing support screws. Tighten the upper headlamp housing support screws to 9 N.m (80 lb in). 5. Install the radiator mounting bolts onto the rear side of the tie bar. Tighten the radiator mounting bolts to 25 N.m (18 lb ft). 6. Install the tie bar to the radiator brace bolts (1). Access the bolts from the rear of the tie bar using an extension. Tighten the radiator brace bolts to 9 N.m (80 lb in). 7. Install the upper fan shroud. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Support Replacement - Radiator Grille Reinforcement > Page 13650 8. Install the front end diagonal brace. 9. Install the front end diagonal brace bolts. Tighten the front end diagonal brace bolts to 25 N.m (18 lb ft). 10. Install the upper condenser mounting bolts. Tighten the upper condenser mounting bolts to 9 N.m (80 lb in). 11. Install the headlamps. 12. Install the upper radiator baffle. 13. Connect the negative battery cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams Power Mirror Control Module: Diagrams Memory Mirror Module Connector C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Page 13655 Memory Mirror Module Connector C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Service and Repair > Procedures Power Mirror Control Module: Procedures The mirror relearn procedure, when initiated, commands the Memory Mirror Module (MMM) to control the driver and then the passenger mirror in the left, right, up and down directions. When commanding the mirrors the MMM also learns the direction of horizontal and vertical position sensor signal circuit feedback voltages. To initiate the relearn procedure, perform the following: 1. With a scan tool, select Memory Mirror Module 2. Select Special Functions 3. Select Output Controls 4. Select Mirror Relearn 5. Then press the Reset button If the mirror relearn procedure does not control the driver and passenger mirrors as described, there may be another fault in the mirror systems. Refer to Diagnostic System Check - Door Systems to begin the diagnosis of the mirror system. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Service and Repair > Procedures > Page 13658 Power Mirror Control Module: Removal and Replacement REMOVAL PROCEDURE 1. Remove the drivers side door panel. 2. Remove the screws (1) that retain the accessory and outside rear view mirror module from the door panel. 3. Remove the nut (2) that retains the accessory and outside rear view mirror module from the door panel. 4. Remove the module from the door panel. INSTALLATION PROCEDURE 1. Install the module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nut (2) that retains the accessory and outside rear view mirror module to the door panel. Tighten Tighten the module retaining nut to 0.6 N.m (5 lb in). 3. Install the screws (1) that retain the accessory and outside rear view mirror module to the door panel. Tighten Tighten the module retaining screws to 0.6 N.m (5 lb in). 4. Install the drivers door panel. 5. Perform the memory mirror module learn procedure. Refer to Memory Mirror Module (MMM) Learn Procedure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 13662 Power Seat Control Module: Diagrams Memory Seat Module - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 13663 Memory Seat Module - C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 13664 Memory Seat Module - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 13665 Power Seat Control Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat trim panel. 2. Remove the seal cushion. 3. Disconnect the harness connectors (2). 4. Remove the memory module retaining screws (1). 5. Slide the module out. 6. Remove the module from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 13666 1. Slide the module in until seated. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the memory module retaining screws (1). Tighten Tighten the screws to 3 N.m (26 lb in). 3. Connect the harness connectors (2). 4. Install the seat cushion. 5. Install the seat trim panel. 6. It a new memory seat module is installed, the seat needs to be synchronized: 6.1. Operate the seat in all directions: ^ Front tilt ^ Rear tilt ^ Horizontal ^ Recline 6.2. If the seat stops part way due to programmed soft stop, release the switch and operate again in the same direction till the seat touches the mechanical stop 6.3. Repeat the above for all seat moving axes. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 13670 Seat Heater Control Module: Diagrams Heated Seat Module - LR Heated Seat Module - RR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof / Moonroof Module: Diagrams Sunroof Module Part 1 Sunroof Module Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Page 13674 Sunroof / Moonroof Module: Service and Repair POWER SUNROOF MODULE REPLACEMENT REMOVAL PROCEDURE 1. The sunroof glass panel must be in the closed position. 2. Remove the headliner. 3. Remove the sunroof glass panel. 4. Remove the drain channel. 5. Remove the sunshade. 6. Remove the 9 bolts retaining the module to the roof. 7. Remove the module from the vehicle. INSTALLATION PROCEDURE 1. Install the module to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Page 13675 2. Loosely install the 9 bolts retaining the module to the roof. Use a drill bit to align the 2 holes (6 and 7). Tighten Tighten the bolts in the sequence shown to 9 N.m (80 lb in). 3. Install the sunshade. 4. Install the drain channel. 5. Install the sunroof glass panel. 6. Install the headliner. 7. Inspect the operation of the sunroof. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Specifications Luggage Rack: Specifications Fastener Tightening Specifications Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Luggage Carrier Replacement (All Except Z-71) Luggage Rack: Service and Repair Luggage Carrier Replacement (All Except Z-71) Luggage Carrier Replacement (All Except Z-71) Removal Procedure 1. Remove the rear pad covers. 2. Remove the cross rails by releasing the lever on both sides and sliding toward rear of vehicle. 3. Remove the side rail attaching bolts. 4. Remove the side rail(s). Installation Procedure 1. Install the side rail(s). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the side rail attaching bolts. Tighten the bolts 4 N.m (35 lb in). 3. Install the cross rails by sliding toward front of vehicle and engaging lever on both sides. 4. Install the rear pad covers by snapping into place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Luggage Carrier Replacement (All Except Z-71) > Page 13682 Luggage Rack: Service and Repair Luggage Carrier Replacement (Avalanche) Luggage Carrier Replacement (Avalanche) Removal Procedure 1. Depress the tabs and remove rear rail covers (2). 2. Remove the rear support retainers. 3. Remove the rear supports and gaskets from the roof (3). 4. Unlock the cross rails (2). 5. Slide the rear and front cross rails from the carrier assembly (1). 6. Remove the retainers from the side rails. 7. Remove the side rail assemblies from the roof. Installation Procedure 1. Install the side rail assemblies (1) to the roof and align to the existing Welnuts. 2. Install the retainers to the side rails and hand tighten. Notice: Refer to Fastener Notice in Service Precautions. 3. Torque the side rail retainers in this order. Tighten the side rail retainers to 2 N.m (20 lb in). 1. Torque the second hole from the front. 2. Torque the first hole. 3. Torque the third and forth holes. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Luggage Carrier Replacement (All Except Z-71) > Page 13683 4. Install the front cross rail assembly (2) to the side rails (1), stopping at the second or third notch from the front of each rail. 5. Depress the adjuster handles to lock each side. 6. Install the rear cross rail to the side rails, stopping at the second or third engagement notch. 7. Depress the adjuster handle to lock each side. 8. Install the rear rail covers (2) by inserting the legs of the cover and rotating cover down to engage the retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Luggage Carrier Replacement (All Except Z-71) > Page 13684 Luggage Rack: Service and Repair Luggage Carrier Replacement (Z-71) Luggage Carrier Replacement (Z-71) Removal Procedure 1. Remove the 2 inboard fasteners from the luggage carrier base covers. 2. Remove the base covers. 3. Remove the fasteners from the front bases. 4. Remove the fasteners (1) from each side of the rear base. 5. Remove the roller bar/rear cross rail assembly (3) from the vehicle. 6. Remove the fasteners (4) from the side rail/rear base. 7. With an assistant, pull gently back on the carrier (1) in order to release the carrier from the supports. 8. With an assistant, lift the carrier assembly up and off the vehicle. 9. Remove the fasteners from the center supports. 10. Remove the center supports with pads from the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Luggage Carrier Replacement (All Except Z-71) > Page 13685 11. Remove the rear base fasteners (2) from the vehicle. 12. Remove the rear bases with pads from the vehicle. Installation Procedure 1. Install the rear bases with pads attached to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear base fasteners (2). Tighten the rear base fasteners to 2 N.m (18 lb in). 3. Install the center supports with pads to the vehicle. 4. Install the support fasteners. Tighten the support fasteners to 3 N.m (27 lb in). 5. With an assistant, lift the carrier (1) to the vehicle roof. 6. With an assistant, set the carrier assembly rails on the rear support assembly and pull forward, locking the carrier to the supports. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Luggage Carrier Replacement (All Except Z-71) > Page 13686 7. Install the fasteners (4) to the side rail/rear base. Tighten the side rail/rear base fasteners to 3 N.m (27 lb in). 8. Install the roller bar/rear cross rail assembly to the vehicle. 9. Install the fasteners (1) to each side of the rear base. Tighten the rear base fasteners to 3 N.m (27 lb in). 10. Install the fasteners to the front bases. Tighten the front base fasteners to 3 N.m (27 lb in). 11. Install the base covers. 12. Install the inboard fasteners to the luggage carrier base covers. Tighten the luggage carrier base cover fasteners to 1.2 N.m (11 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair Sun Shade: Service and Repair SUNSHADE PANEL REPLACEMENT REMOVAL PROCEDURE 1. Remove the glass panel. 2. Remove the drain channel. 3. With the sunshade (1) in the closed position, push front (either side) sunshade spring (glider) (2) inward and release glider from the track. Gently pull same corner of the sunshade outward and wiggle remaining gliders out of the track. INSTALLATION PROCEDURE 1. Install sunshade (1) and place both gliders on one side into track. Now compress one of the other gliders (2) inward and slide into track. Repeat this procedure for the last glider. 2. With the sunshade in halt open position, install the drain channel. 3. Install the glass panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Power Sunroof Motor Replacement Sunroof / Moonroof Motor: Service and Repair Power Sunroof Motor Replacement REMOVAL PROCEDURE 1. Remove the headliner. 2. Disconnect the wire harness from the sunroof motor. 3. Remove the 2 screws retaining the motor. 4. Pull the motor from the unit. Some gentle back and forth rotation may be required to release the motor gear from drive cables. INSTALLATION PROCEDURE 1. install the sunroof motor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 2 screws. Tighten Tighten the screws to 3 N.m (27 lb in). 3. Connect the wire harness to the sunroof motor. 4. Install the headliner. 5. Inspect the operation of the sunroof. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Power Sunroof Motor Replacement > Page 13695 Sunroof / Moonroof Motor: Service and Repair Sunroof Motor Synchronization Synchronization will be necessary anytime the sunroof module battery positive voltage circuit is interrupted. The sunroof module will be synchronized when the controller learns the full vent position. The sunroof system will ignore any open request until the system has been synchronized. To synchronize the sunroof: 1. Turn ON the ignition, with the engine OFF. 2. Using the close/tilt up portion of the sunroof switch, operate the sunroof glass until it reaches the full vent position. 3. Verify that the system operates normally. Once the sunroof glass reaches the full vent position, the actual position is stored in the memory of the sunroof module. The sunroof module will stop the motor one motor revolution before the defined actual positions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams Sunroof Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 13699 Sunroof / Moonroof Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the roof console assembly. 2. Disconnect the electrical connector. 3. Remove the switch by un-snapping from roof console assembly. INSTALLATION PROCEDURE 1. Install the switch to roof console assembly by snapping into place. 2. Connect the electrical connector. 3. Install the roof console assembly. 4. Synchronize the sunroof motor. Refer to Sunroof Motor Synchronization. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-67-002 > Apr > 02 > Headliner/Roof - Rattles Sunroof / Moonroof Drain: Customer Interest Headliner/Roof - Rattles File In Section: 08 - Body and Accessories Bulletin No.: 02-08-67-002 Date: April, 2002 TECHNICAL Subject: Headliner Or Roof Rattle (Replace Roof Drain Channel With New Design Channel) Models: 2002 Cadillac Escalade 2002 Chevrolet and GMC C/K Utility Models (Suburban, Tahoe, Yukon, Yukon Denali, Yukon Denali XL) Built at Janesville and Arlington (Plant Codes J, R) Built between February 1 and February 18, 2002 Condition Some customers may comment on a rattle in the roof or headliner. Cause The sunroof drain channel may have insufficient mounting tabs which causes the water channel to disengage from the rear clips. Correction 1. Operate the sunroof glass to the full vent position. Important: The water channel edges are sharp. 2. From inside of the vehicle, facing rearward, reach up into the sunroof opening with both hands. On the drivers side, using your right hand, push back against the drain channel retaining clip at the top mounting point. Refer to the arrow in the illustration above. At the same time, pull on the rear flange of the drain channel with your left hand. The drain channel should release from the clip. 3. Repeat for passenger side using the opposite hands. After both clips have been released, push the drain channel toward the rear of the vehicle to release the drain channel from the front tabs. Remove the drain channel out through the inside of the vehicle. 4. Install the new design drain channel. 5. Push the drain channel into the opening past the front retaining clips. Place the front flanges of the channel to the front mounting tabs and insent into the tabs. The flanges must be underneath the mounting tabs. 6. Push downward on the drain channel. You should hear two sharp snaps indicating that the rear drain channel retaining clips have been installed. 7. Test the installation by trying to lift the front facing edges. The water channel should not move. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-67-002 > Apr > 02 > Headliner/Roof - Rattles > Page 13708 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-08-67-002 > Apr > 02 > Headliner/Roof - Rattles Sunroof / Moonroof Drain: All Technical Service Bulletins Headliner/Roof - Rattles File In Section: 08 - Body and Accessories Bulletin No.: 02-08-67-002 Date: April, 2002 TECHNICAL Subject: Headliner Or Roof Rattle (Replace Roof Drain Channel With New Design Channel) Models: 2002 Cadillac Escalade 2002 Chevrolet and GMC C/K Utility Models (Suburban, Tahoe, Yukon, Yukon Denali, Yukon Denali XL) Built at Janesville and Arlington (Plant Codes J, R) Built between February 1 and February 18, 2002 Condition Some customers may comment on a rattle in the roof or headliner. Cause The sunroof drain channel may have insufficient mounting tabs which causes the water channel to disengage from the rear clips. Correction 1. Operate the sunroof glass to the full vent position. Important: The water channel edges are sharp. 2. From inside of the vehicle, facing rearward, reach up into the sunroof opening with both hands. On the drivers side, using your right hand, push back against the drain channel retaining clip at the top mounting point. Refer to the arrow in the illustration above. At the same time, pull on the rear flange of the drain channel with your left hand. The drain channel should release from the clip. 3. Repeat for passenger side using the opposite hands. After both clips have been released, push the drain channel toward the rear of the vehicle to release the drain channel from the front tabs. Remove the drain channel out through the inside of the vehicle. 4. Install the new design drain channel. 5. Push the drain channel into the opening past the front retaining clips. Place the front flanges of the channel to the front mounting tabs and insent into the tabs. The flanges must be underneath the mounting tabs. 6. Push downward on the drain channel. You should hear two sharp snaps indicating that the rear drain channel retaining clips have been installed. 7. Test the installation by trying to lift the front facing edges. The water channel should not move. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-08-67-002 > Apr > 02 > Headliner/Roof - Rattles > Page 13714 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Drain: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Drain: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 13720 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Drain: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 13721 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Drain: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 13722 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Drain: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 13728 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Drain: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 13729 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Drain: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 13730 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Channel Replacement Sunroof / Moonroof Drain: Service and Repair Drain Channel Replacement Drain Channel Replacement Removal Procedure 1. Remove the sunroof glass panel. 2. On one side of the drain channel (1), push the tab (3) rearwards and lift up the drain channel. Do the same for the other side. 3. Slide the drain channel from the guide (2). Installation Procedure 1. Slide the drain channel into the guide tab (2). 2. Push on the drain channel (1) until it locks into place by the retainer (3). Do the same for the other side. 3. Ensure both sides are properly seated in the guide. 4. Install the sunroof glass panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Channel Replacement > Page 13733 Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Hose Replacement - Front Sunroof Drain Hose Replacement - Front Removal Procedure 1. Remove the garnish molding/windshield pillar. 2. Remove the sunshades. 3. Pull down the corner of the headliner. 4. Remove the hose from module nozzle. 5. Remove the hose from the clip. 6. Remove the hose. Installation Procedure 1. Install the hose. 2. Install the hose to clip. 3. Install the hose to module nozzle. 4. Be sure the seal is fully seated to plenum and hose is bottomed out against nozzle. 5. Inspect for kinks in the hose. 6. Push up the corner of headliner. 7. Install the sunshades. 8. Install the garnish molding/windshield pillar. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Channel Replacement > Page 13734 Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Hose Replacement - Rear Sunroof Drain Hose Replacement - Rear Removal Procedure 1. Remove the center pillar trim. 2. Remove the headliner. 3. Remove the drain hose from the nozzles rear, corner and side, assuring butyl tape is removed. 4. Remove the clip retaining hose to sheet metal. 5. Remove the grommet from the sealer plate. 6. Pull the hose away from sheet metal where attached with butyl tape. 7. Remove the hose. Installation Procedure 1. Install the hose. 2. Re-locate the hose to sheet metal where attached with butyl tape. 3. Install the grommet to sealer plate. 4. Install the clip retaining hose to the sheet metal. 5. Install the hose to nozzles rear, corner and side, assure butyl tape is in position. 6. Install the headliner. 7. Install the center pillar trim. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame: > 02-08-67-009A > May > 05 > Body - Sunroof Jams Upon Closing Sunroof / Moonroof Frame: Customer Interest Body - Sunroof Jams Upon Closing Bulletin No.: 02-08-67-009A Date: May 16, 2005 TECHNICAL Subject: Sunroof Jams When Closing (Install Guides) Models: 2002-2005 Cadillac Escalade, Escalade EXT 2002-2005 Chevrolet Avalanche, Suburban, Tahoe 2002-2005 GMC Yukon, Yukon XL, Yukon Denali, Yukon XL Denali Supercede: This bulletin is being revised to add the 2004-2005 model years. Please discard Corporate Bulletin Number 02-08-67-009 (Section 08 - Body and Accessories). Condition Some customers may comment that the sunroof jams when closing. Cause The sunshade clips may have come loose causing the sunroof to jam and break the guides. Refer to the illustration above. Correction 1. Remove the sunshade and the sunroof. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame: > 02-08-67-009A > May > 05 > Body - Sunroof Jams Upon Closing > Page 13743 2. Remove the Phillips screw from the small guide and set the guide aside. Refer to the illustration above. 3. Remove the two retaining clips from the front and rear guide and set the arm aside. 4. Pull upward on the arm assembly and move it outward. Refer to the illustration above. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame: > 02-08-67-009A > May > 05 > Body - Sunroof Jams Upon Closing > Page 13744 5. Pull upward on the end of the front guide and rotate outward to remove it from the track. Refer to the illustration above. 6. Slide the rear guide rearward to remove. 7. Replace the stop under the sunroof channel. Refer to the illustration above. 8. Replace the guides on the sunshade. Refer to the illustration above. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame: > 02-08-67-009A > May > 05 > Body - Sunroof Jams Upon Closing > Page 13745 Parts Information Parts are currently available form GMSPO. Warranty Information For vehicles repaired under warranty, use table. gm_disclaimer-001 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Frame: > 02-08-67-009A > May > 05 > Body - Sunroof Jams Upon Closing Sunroof / Moonroof Frame: All Technical Service Bulletins Body - Sunroof Jams Upon Closing Bulletin No.: 02-08-67-009A Date: May 16, 2005 TECHNICAL Subject: Sunroof Jams When Closing (Install Guides) Models: 2002-2005 Cadillac Escalade, Escalade EXT 2002-2005 Chevrolet Avalanche, Suburban, Tahoe 2002-2005 GMC Yukon, Yukon XL, Yukon Denali, Yukon XL Denali Supercede: This bulletin is being revised to add the 2004-2005 model years. Please discard Corporate Bulletin Number 02-08-67-009 (Section 08 - Body and Accessories). Condition Some customers may comment that the sunroof jams when closing. Cause The sunshade clips may have come loose causing the sunroof to jam and break the guides. Refer to the illustration above. Correction 1. Remove the sunshade and the sunroof. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Frame: > 02-08-67-009A > May > 05 > Body - Sunroof Jams Upon Closing > Page 13751 2. Remove the Phillips screw from the small guide and set the guide aside. Refer to the illustration above. 3. Remove the two retaining clips from the front and rear guide and set the arm aside. 4. Pull upward on the arm assembly and move it outward. Refer to the illustration above. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Frame: > 02-08-67-009A > May > 05 > Body - Sunroof Jams Upon Closing > Page 13752 5. Pull upward on the end of the front guide and rotate outward to remove it from the track. Refer to the illustration above. 6. Slide the rear guide rearward to remove. 7. Replace the stop under the sunroof channel. Refer to the illustration above. 8. Replace the guides on the sunshade. Refer to the illustration above. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Frame: > 02-08-67-009A > May > 05 > Body - Sunroof Jams Upon Closing > Page 13753 Parts Information Parts are currently available form GMSPO. Warranty Information For vehicles repaired under warranty, use table. gm_disclaimer-001 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof / Moonroof Module: Diagrams Sunroof Module Part 1 Sunroof Module Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Page 13757 Sunroof / Moonroof Module: Service and Repair POWER SUNROOF MODULE REPLACEMENT REMOVAL PROCEDURE 1. The sunroof glass panel must be in the closed position. 2. Remove the headliner. 3. Remove the sunroof glass panel. 4. Remove the drain channel. 5. Remove the sunshade. 6. Remove the 9 bolts retaining the module to the roof. 7. Remove the module from the vehicle. INSTALLATION PROCEDURE 1. Install the module to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Page 13758 2. Loosely install the 9 bolts retaining the module to the roof. Use a drill bit to align the 2 holes (6 and 7). Tighten Tighten the bolts in the sequence shown to 9 N.m (80 lb in). 3. Install the sunshade. 4. Install the drain channel. 5. Install the sunroof glass panel. 6. Install the headliner. 7. Inspect the operation of the sunroof. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair Sunroof / Moonroof Panel: Service and Repair SUNROOF GLASS PANEL REPLACEMENT REMOVAL PROCEDURE 1. Pull back the sunshade. 2. Set the sunroof in the closed position. 3. From inside of the vehicle remove the 4 glass panel adjustment screws. 4. From inside of the vehicle push up on the sunroof glass panel so that the glass panel can be grabbed and lifted from the roof opening. 5. Remove the glass panel from the roof opening. INSTALLATION PROCEDURE 1. Ensure the glass panel mechanism is in the closed position. 2. From outside the vehicle, carefully place the glass panel onto the mechanism. 3. Loosely install the 4 adjustment screws. IMPORTANT: Required position of the glass panel is when the front and rear of the sunroof glass panel is flushed with the roof panel. 4. Align the glass panel. Refer to Sunroof Glass Height and Opening Fit Adjustment. 5. Inspect the operation of the sunroof. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Wiring Harness > Component Information > Service and Repair Sunroof / Moonroof Wiring Harness: Service and Repair REMOVAL PROCEDURE 1. Remove the headliner. IMPORTANT: Observe the routing of the wire harness. Failure to route the wire the same will result in the wire harness being pinched during sunroof operation. 2. Disconnect the wire harness connectors (5) and (6). 3. Remove the wire from the sunroof module. INSTALLATION PROCEDURE 1. Connect the wire connector (6). IMPORTANT: Do not route the wire harness on the top or the bottom of the flange as it will get pinched during sunroof operation. 2. Secure the wire harness along the out board flange (7) and (2). 3. Secure clip (1) and clip (3) to sunroof module flange. 4. Loop the wire harness around cable drive (4). 5. Connect the wire harness (5) to the sunroof motor. 6. Install the headliner. 7. Inspect the operation of the sunroof. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > Recalls for Head Rest: > 02039 > Nov > 02 > Recall - 2nd Row Seat Head Restraint Pinch Points Technical Service Bulletin # 02039 Date: 021101 Recall - 2nd Row Seat Head Restraint Pinch Points File In Section: Product Recalls Bulletin No.: 02039 Date: November, 2002 PRODUCT SAFETY RECALL SUBJECT: 02039 - REARWARD FOLDING HEAD RESTRAINTS PINCH POINT MODELS: 2000-2002 CHEVROLET TAHOE 2000-2002 GMC YUKON 2001-2002 GMC YUKON DENALI 2002 CADILLAC ESCALADE CONDITION General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2000-2002 Chevrolet Tahoes; 2000-2002 GMC Yukons; 2001-2002 GMC Yukon Denalis; and 2002 Cadillac Escalades equipped with rearward folding head restraints on the second row seats. Two potential pinch points exist on each of the folding head restraints when the head restraint(s) are folded rearward as the seatback is folded down. If a person were to insert their finger(s) into the pinch point when the head restraint folds, it could trap and pinch the finger(s) causing injury. CORRECTION Dealers are to install protective covers over the pinch points. VEHICLES INVOLVED Involved are certain 2000-2002 Chevrolet Tahoes; 2000-2002 GMC Yukons; 2001-2002 GMC Yukon Denalis; and 2002 Cadillac Escalades equipped with rearward folding head restraints on the second row seat and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > Recalls for Head Rest: > 02039 > Nov > 02 > Recall - 2nd Row Seat Head Restraint Pinch Points > Page 13774 PARTS INFORMATION Parts Pre-Ship Information - For US and Canada Important: An initial supply of parts required to complete this program will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of October 28, 2002. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. RECALL IDENTIFICATION LABEL For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Request Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a type writer or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > Recalls for Head Rest: > 02039 > Nov > 02 > Recall - 2nd Row Seat Head Restraint Pinch Points > Page 13775 service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > Recalls for Head Rest: > 02039 > Nov > 02 > Recall - 2nd Row Seat Head Restraint Pinch Points > Page 13776 DISCLAIMER Service Procedure The following are instructions for installing support covers on the SECOND ROW rear seat head restraints. There are a total of four (4) covers to be installed (two per head restraint). 1. Open the rear side doors for access to the second row seat. 2. Release both rear seat cushions by pulling up on the strap loops located at the rear center of each seat cushion. Once released, continue pulling the seat cushion up and then fold it forward. Caution Keep fingers away from the pinch points when the head restraints fold rearward as the seatback is being lowered in the next step. 3. Raise both second row rear seat head restraints to the full up position and tilt both rear seatbacks forward. 4. Insert an awl or pointed tool into the small hole (1) in the retainer located at the bottom of the head restraint while slightly pulling upward on the restraint. Repeat this step on the second support of the head restraint. 5. Remove the head restraint. 6. Raise the head restraint supports (1) to a vertical position and carefully open the slit (3) in the seatback fabric (2). The illustration shows the left slit being closed and the right slit when open. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > Recalls for Head Rest: > 02039 > Nov > 02 > Recall - 2nd Row Seat Head Restraint Pinch Points > Page 13777 7. Install one support cover (4) on the head restraint support (1) with the support going through the hole in the cover. 8. While holding the slit (3) in the seatback fabric open, begin sliding the cover down inside the seatback as shown. 9. When the support cover (4) is all the way down on the head restraint support (1), fold (tilt) the head restraint support rearward as shown. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > Recalls for Head Rest: > 02039 > Nov > 02 > Recall - 2nd Row Seat Head Restraint Pinch Points > Page 13778 10. With the head restraint support (1) folded rearward, finish inserting the support cover (4) inside the slit (3) in the seatback. Reposition the seatback fabric as necessary to close the slit in the fabric. 11. Install a support cover on the other head restraint support. 12. Install the head restraint on the supports and verify that the head restraint supports fold properly. 13. Repeat the above procedure on the other second row head restraint supports. 14. Return the seatbacks and cushions to their normal positions. 15. Install the GM Recall Identification Label. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > Recalls for Head Rest: > 02039 > Nov > 02 > Recall - 2nd Row Seat Head Restraint Pinch Points > Page 13779 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > Recalls for Head Rest: > 02039 > Nov > 02 > Recall - 2nd Row Seat Head Restraint Pinch Points > Page 13780 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > Recalls for Head Rest: > NHTSA02V253000 > Sep > 02 > Recall 02V253000: Head Restraint Pinch Point Cover Head Rest: Recalls Recall 02V253000: Head Restraint Pinch Point Cover DEFECT: On certain sport utility vehicles equipped with rearward folding head restraints on the second row seats, two potential pinch points exist on each of the folding head restraints when the restraints are folded rearward as the seatback is folded down. If a person were to insert his or her finger into the pinch point when the head restraint folds, it could trap and pinch the finger, causing injury. REMEDY: Dealers will install protective covers over the pinch points. The manufacturer has reported that owner notification is expected to begin during November 2002. Owners should contact Chevrolet at 1-800-222-1020, GMC at 1-800-462-8782, or Cadillac at 1-800-458-8006. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Head Rest: > 02039 > Nov > 02 > Recall - 2nd Row Seat Head Restraint Pinch Points Technical Service Bulletin # 02039 Date: 021101 Recall - 2nd Row Seat Head Restraint Pinch Points File In Section: Product Recalls Bulletin No.: 02039 Date: November, 2002 PRODUCT SAFETY RECALL SUBJECT: 02039 - REARWARD FOLDING HEAD RESTRAINTS PINCH POINT MODELS: 2000-2002 CHEVROLET TAHOE 2000-2002 GMC YUKON 2001-2002 GMC YUKON DENALI 2002 CADILLAC ESCALADE CONDITION General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2000-2002 Chevrolet Tahoes; 2000-2002 GMC Yukons; 2001-2002 GMC Yukon Denalis; and 2002 Cadillac Escalades equipped with rearward folding head restraints on the second row seats. Two potential pinch points exist on each of the folding head restraints when the head restraint(s) are folded rearward as the seatback is folded down. If a person were to insert their finger(s) into the pinch point when the head restraint folds, it could trap and pinch the finger(s) causing injury. CORRECTION Dealers are to install protective covers over the pinch points. VEHICLES INVOLVED Involved are certain 2000-2002 Chevrolet Tahoes; 2000-2002 GMC Yukons; 2001-2002 GMC Yukon Denalis; and 2002 Cadillac Escalades equipped with rearward folding head restraints on the second row seat and built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Head Rest: > 02039 > Nov > 02 > Recall - 2nd Row Seat Head Restraint Pinch Points > Page 13790 PARTS INFORMATION Parts Pre-Ship Information - For US and Canada Important: An initial supply of parts required to complete this program will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of October 28, 2002. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. RECALL IDENTIFICATION LABEL For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Request Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a type writer or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Head Rest: > 02039 > Nov > 02 > Recall - 2nd Row Seat Head Restraint Pinch Points > Page 13791 service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Head Rest: > 02039 > Nov > 02 > Recall - 2nd Row Seat Head Restraint Pinch Points > Page 13792 DISCLAIMER Service Procedure The following are instructions for installing support covers on the SECOND ROW rear seat head restraints. There are a total of four (4) covers to be installed (two per head restraint). 1. Open the rear side doors for access to the second row seat. 2. Release both rear seat cushions by pulling up on the strap loops located at the rear center of each seat cushion. Once released, continue pulling the seat cushion up and then fold it forward. Caution Keep fingers away from the pinch points when the head restraints fold rearward as the seatback is being lowered in the next step. 3. Raise both second row rear seat head restraints to the full up position and tilt both rear seatbacks forward. 4. Insert an awl or pointed tool into the small hole (1) in the retainer located at the bottom of the head restraint while slightly pulling upward on the restraint. Repeat this step on the second support of the head restraint. 5. Remove the head restraint. 6. Raise the head restraint supports (1) to a vertical position and carefully open the slit (3) in the seatback fabric (2). The illustration shows the left slit being closed and the right slit when open. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Head Rest: > 02039 > Nov > 02 > Recall - 2nd Row Seat Head Restraint Pinch Points > Page 13793 7. Install one support cover (4) on the head restraint support (1) with the support going through the hole in the cover. 8. While holding the slit (3) in the seatback fabric open, begin sliding the cover down inside the seatback as shown. 9. When the support cover (4) is all the way down on the head restraint support (1), fold (tilt) the head restraint support rearward as shown. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Head Rest: > 02039 > Nov > 02 > Recall - 2nd Row Seat Head Restraint Pinch Points > Page 13794 10. With the head restraint support (1) folded rearward, finish inserting the support cover (4) inside the slit (3) in the seatback. Reposition the seatback fabric as necessary to close the slit in the fabric. 11. Install a support cover on the other head restraint support. 12. Install the head restraint on the supports and verify that the head restraint supports fold properly. 13. Repeat the above procedure on the other second row head restraint supports. 14. Return the seatbacks and cushions to their normal positions. 15. Install the GM Recall Identification Label. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Head Rest: > 02039 > Nov > 02 > Recall - 2nd Row Seat Head Restraint Pinch Points > Page 13795 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Head Rest: > 02039 > Nov > 02 > Recall - 2nd Row Seat Head Restraint Pinch Points > Page 13796 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Head Rest: > NHTSA02V253000 > Sep > 02 > Recall 02V253000: Head Restraint Pinch Point Cover Head Rest: All Technical Service Bulletins Recall 02V253000: Head Restraint Pinch Point Cover DEFECT: On certain sport utility vehicles equipped with rearward folding head restraints on the second row seats, two potential pinch points exist on each of the folding head restraints when the restraints are folded rearward as the seatback is folded down. If a person were to insert his or her finger into the pinch point when the head restraint folds, it could trap and pinch the finger, causing injury. REMEDY: Dealers will install protective covers over the pinch points. The manufacturer has reported that owner notification is expected to begin during November 2002. Owners should contact Chevrolet at 1-800-222-1020, GMC at 1-800-462-8782, or Cadillac at 1-800-458-8006. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement Head Rest: Service and Repair Head Restraint Replacement REMOVAL PROCEDURE 1. Raise the head restraint (1) to the full up position. 2. Insert a paper clip or a similar tool in the hole at the side edges of the head restraint retainers. 3. Press in on the tool in order to release the retainer clips (2). 4. Lift the head restraint from the retainers. INSTALLATION PROCEDURE 1. Install the head restraint (1) into the retainers. 2. Push the head restraint to the full down position. 3. Pull up in order to ensure that the head restraint engages with the head restraint retainers (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement > Page 13803 Head Rest: Service and Repair Head Restraint Replacement (Folding) Head Restraint Replacement (Folding) Removal Procedure 1. Pull the folding seatback cover in order to disengage the folding seatback cover from the retaining clips. Remove the folding seatback cover. 2. Raise the head restraint (1) to the full-up position. 3. Insert a pointed tool into the hole in the head restraint retainers. 4. Lift the head restraint from the retainers. 5. Remove the seat back cover and pad from the seat. 6. Remove the seat-back recliner handle screw from the mounting bracket. 7. Remove the seat back recliner handle. 8. Remove the bolts that retain the folding head restraint assembly to the front of the seat frame. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement > Page 13804 9. Remove the bolts that retain the folding head restraint assembly to the back of the seat frame. 10. Remove the cable from the folding head restraint assembly. 11. Remove the head restraint assembly from the vehicle. Installation Procedure 1. Install the head restraint assembly to the vehicle. 2. Install the cable to the folding head restraint assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts that retain the folding head restraint assembly to the back of the seat frame. Tighten the bolts to 7 N.m (61 lb in). 4. Install the bolts that retain the folding head restraint assembly to the front of the seat frame. Tighten the bolts to 7 N.m (61 lb in). 5. Install the seat back recliner handle. 6. Install the seat-back recliner handle screw to the mounting bracket. Tighten the screw to 2 N.m (18 lb in). 7. Install the seat back cover and pad to the seat. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement > Page 13805 8. Install the head restraint (1) to the seat by pushing down in order to engage the retaining clips. 9. Install the folding seatback cover by pushing down in order to engage the retaining clips. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement > Page 13806 Head Rest: Service and Repair Head Restraint Replacement (Non-Cadillac) Head Restraint Replacement (Non-Cadillac) Removal Procedure 1. Raise the head restraint (1) to the full up position. 2. Insert a paper clip or a similar tool in the hole at the side edges of the head restraint retainers. 3. Press in on the tool in order to release the retainer clips (2). 4. Lift the head restraint from the retainers. Installation Procedure 1. Install the head restraint (1) into the retainers. 2. Push the head restraint to the full down position. 3. Pull up in order to ensure that the head restraint engages with the head restraint retainers (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement > Page 13807 Head Rest: Service and Repair Head Restraint Retainer Replacement - Front Seat Head Restraint Retainer Replacement - Front Seat Removal Procedure 1. Slide up the seat back trim cover in order to gain access to the rear cardboard panel fasteners. Refer to Seat Back Cover and Pad Replacement Front. 2. Remove the panel fasteners. Pull back the panel in order to gain access to the bushings. 3. Remove the head restraint retainers from the seat back frame by squeezing the retaining tabs together at the base of the guide(s) and lifting up. Installation Procedure 1. Install the head restraint retainers by pressing into the seat back frame until the retaining tabs snap into place at the bottom of the frame opening. 2. Position the cardboard panel to the seat back frame and install the panel fasteners. 3. Install the seat back trim cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Locations > Page 13815 Power Seat Control Module: Diagrams Memory Seat Module - C1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Locations > Page 13816 Memory Seat Module - C2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Locations > Page 13817 Memory Seat Module - C3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Locations > Page 13818 Power Seat Control Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat trim panel. 2. Remove the seal cushion. 3. Disconnect the harness connectors (2). 4. Remove the memory module retaining screws (1). 5. Slide the module out. 6. Remove the module from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Locations > Page 13819 1. Slide the module in until seated. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the memory module retaining screws (1). Tighten Tighten the screws to 3 N.m (26 lb in). 3. Connect the harness connectors (2). 4. Install the seat cushion. 5. Install the seat trim panel. 6. It a new memory seat module is installed, the seat needs to be synchronized: 6.1. Operate the seat in all directions: ^ Front tilt ^ Rear tilt ^ Horizontal ^ Recline 6.2. If the seat stops part way due to programmed soft stop, release the switch and operate again in the same direction till the seat touches the mechanical stop 6.3. Repeat the above for all seat moving axes. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations Power Seat Motor: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 13823 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor Power Seat Motor: Diagrams Seat Recliner Motor Seat Recliner Motor - Driver Seat Recliner Motor - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor > Page 13826 Power Seat Motor: Diagrams Seat Bolster Motor Seat Bolster Motor - Driver Seat Bolster Motor - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor > Page 13827 Power Seat Motor: Diagrams Seat Front Vertical Motor Seat Front Vertical Motor - Front Passenger Seat Front Vertical Motor - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor > Page 13828 Power Seat Motor: Diagrams Seat Horizontal Motor Seat Horizontal Motor - Driver Seat Horizontal Motor - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor > Page 13829 Power Seat Motor: Diagrams Seat Recliner Motor - Driver Seat Recliner Motor - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor > Page 13830 Seat Bolster Motor - Driver Seat Bolster Motor - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor > Page 13831 Seat Front Vertical Motor - Front Passenger Seat Front Vertical Motor - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor > Page 13832 Seat Horizontal Motor - Driver Seat Horizontal Motor - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor > Page 13833 Seat Lumbar Motor - Driver Seat Lumbar Motor - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor > Page 13834 Seat Rear Vertical Motor - Driver Seat Rear Vertical Motor - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat Adjuster Replacement - Front (Manual) Power Seat Motor: Service and Repair Seat Adjuster Replacement - Front (Manual) Seat Adjuster Replacement - Front (Manual) Removal Procedure 1. Remove the front seat from the vehicle. 2. Remove the seat trim panel. 3. Remove the seat cushion frame. 4. Remove the seat back frame. 5. Remove the seat back hinge/recliner mechanism. 6. Remove the seat adjuster track cover. 7. Remove the inboard seat belt buckle and nut (1). Disconnect the electrical connection (2). 8. Remove the bar (1) from the adjuster tracks (2). Straighten the tabs in order to remove the bar. 9. Remove the cross brace (3). 10. Remove the EZ entry rod (4), if equipped with the EZ entry feature. 11. Remove the cushion tilt mechanism, if equipped. Installation Procedure 1. Install the cushion tilt mechanism, if equipped. 2. Install the EZ entry rod (4), if equipped with the EZ entry feature. 3. Install the cross brace (3). 4. Install the bar (1) onto the racks (2). Bend the tabs in order to secure the bar. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat Adjuster Replacement - Front (Manual) > Page 13837 Notice: Refer to Fastener Notice in Service Precautions. 5. Install the inboard seat belt buckle and nut (1). Tighten the nut to 53 N.m (39 lb ft). 6. Connect the electrical connection (2). 7. Install the seat adjuster track cover. 8. Install the seat back hinge/recliner mechanism. 9. Install the seat back frame. 10. Install the seat cushion frame. 11. Install the seat trim panel. 12. Install the front seat in the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat Adjuster Replacement - Front (Manual) > Page 13838 Power Seat Motor: Service and Repair Seat Adjuster Replacement - Front (Power) Seat Adjuster Replacement - Front (Power) Removal Procedure 1. Remove the front seat from the vehicle. 2. Remove the seat trim panel. 3. Remove the seat cushion frame from the seat adjuster. 4. Remove the inboard seat belt buckle and nut (1). Disconnect the electrical connection (2). 5. Remove the seat back frame from the seat adjuster. 6. Remove the seat back hinge/recliner mechanism.. 7. Remove the seat adjuster track cover. 8. Remove the memory module, if equipped. Installation Procedure 1. Install the memory module, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the inboard seat belt buckle and nut (1). Tighten the nut to 53 N.m (39 lb ft). 3. Connect the electrical connection (2). 4. Install the seat adjuster track cover. 5. Install the seat back hinge/recliner mechanism. 6. Install the seat back frame to the seat adjuster. 7. Install the seat cushion frame to the seat adjuster. 8. Install the seat trim panel. 9. Install the seat in the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Recliner Motor Position Sensor - Driver Seat Recliner Motor Position Sensor - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Recliner Motor Position Sensor - Driver > Page 13843 Seat Front Vertical Motor Position Sensor - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Recliner Motor Position Sensor - Driver > Page 13844 Seat Horizontal Motor Position Sensor - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Recliner Motor Position Sensor - Driver > Page 13845 Seat Rear Vertical Motor Position Sensor - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: Customer Interest Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing > Page 13854 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: All Technical Service Bulletins Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing > Page 13860 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch Power Seat Switch: Diagrams Lumbar/Bolster Switch Lumbar/Bolster Switch - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch > Page 13863 Lumbar/Bolster Switch - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch > Page 13864 Power Seat Switch: Diagrams Seat Adjuster Switch Seat Adjuster Switch - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch > Page 13865 Seat Adjuster Switch - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch > Page 13866 Seat Adjuster Switch - Driver - Full Feature Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch > Page 13867 Seat Adjuster Switch - Front Passenger - Full Feature Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Switch Bezel Replacement Power Seat Switch: Service and Repair Seat Switch Bezel Replacement Seat Switch Bezel Replacement Removal Procedure 1. Remove the lumbar knob, if equipped. 2. Remove the screws retaining the power seat switch bezel. 3. Disconnect the electrical connectors. 4. Remove the lumbar support switch. 5. Remove the power seat adjuster switch assembly. Installation Procedure 1. Install the power seat adjuster switch assembly to the seat switch bezel. 2. Install the lumbar support switch to the seat switch bezel. 3. Connect the electrical connectors. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the screws retaining the power seat switch bezel. Tighten the screws to 2 N.m (18 lb in). 5. Install the lumbar knob, if equipped. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Switch Bezel Replacement > Page 13870 Power Seat Switch: Service and Repair Seat Switch Replacement - Power Seat Switch Replacement - Power Removal Procedure 1. Remove the lumbar knob, if equipped. 2. Remove the power seat switch bezel from the seat. 3. Remove the power seat switch to bezel screws. 4. Remove the power seat switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten the screws to 2 N.m (18 lb in). 2. Install the power seat switch bezel to the seat. 3. Install the lumbar knob, if equipped. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Switch Bezel Replacement > Page 13871 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Removal Procedure 1. Remove the power seat switch bezel containing the lumbar switch (1) from the seat. 2. Remove the lumbar switch screws from the power seat switch bezel. 3. Remove the lumbar switch. Installation Procedure 1. Install the lumbar switch to the power seat switch bezel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the lumbar switch screws. Tighten the screws to 2 N.m (18 lb in). 3. Install the power seat switch bezel (1) to the seat. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front Seat Back Frame: Service and Repair Seat Back Frame Replacement - Front REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the head restraint and guides. 3. Remove the seat trim panel. 4. Disconnect the lumbar cable (6) underneath the seat cushion (disconnect the lumbar wire harness if equipped with power lumbar). 5. Remove the seat back trim cover and pad. 6. Remove the lumbar assembly (or power lumbar/bolster assembly if equipped). 7. Remove the seat belt retractor. 8. Remove the inboard pivot bolt (1). 9. Remove the recliner arm attachment bolts (2). 10. Remove the frame from the vehicle. 11. Transfer all necessary components to the new seat back frame. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 13877 1. Position the seat back frame on the seat. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the recliner arm attachment bolts (2). Tighten Tighten the bolts to 53 N.m (39 lb ft). 3. Install the inboard pivot bolt (1). Tighten Tighten the bolt to 35 N.m (26 lb ft). 4. Install the seat belt retractor. 5. Install the lumbar assembly (or power lumbar/bolster assembly if equipped). 6. Install the seat back trim cover and pad. 7. Connect the lumbar cable (6) underneath the seat cushion (disconnect the wire harness if equipped with power lumbar). 8. Install the seat trim panel. 9. Install the head restraint and guides. 10. Install the seat into the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 13878 Seat Back Frame: Service and Repair Seat Back Frame Replacement - Rear REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the armrest, if equipped. 3. Partially remove the seat-back cover in order to gain access to the retaining bolts. 4. Remove the bolts from the seat-back frame. 5. Remove the seat-back frame (4) from the seat back cushion frame. INSTALLATION PROCEDURE 1. Install the seat-back frame (4) to the seat cushion frame. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts which retain the seat-back frame to the seat cushion frame. Tighten Tighten to 35 N.m (26 lb ft). 3. Install the seat-back cover. 4. Install the armrest to the seat back. 5. Install the seat to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 13883 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 13884 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 13885 Seat Cover: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 13886 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 13887 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 13888 Seat Cover: Technical Service Bulletins Interior - Napped Seat Fabric Repair Bulletin No.: 04-08-50-011A Date: May 04, 2006 INFORMATION Subject: Repairing Napped Seat Fabric Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 1999-2006 Chevrolet Silverado 2000-2007 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Astro 2002-2006 Chevrolet Monte Carlo 2002-2007 Chevrolet Avalanche 2002-2005 GMC Safari 2007 GMC Yukon, Yukon XL 2002-2004 Oldsmobile Alero 1997-2006 Pontiac Grand Prix Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 04-08-50-011 (Section 08 - Body & Accessories). This bulletin is being issued to advise technicians/dealers on the proper repair required when a customer brings in a trimmed seat with the appearance of being worn, having a bald spot and/or being discolored. The seats in the later vehicles are trimmed with a cloth that has a napped fabric. Under some circumstances, the nap may become crushed down by normal use, giving the appearance of being worn out. If the base material is NOT visible, use a small brass (NOT STEEL) wire brush to carefully fluff and raise the nap. The wire brush (fine bristle brass) is available at most hardware and home stores. If the base material is visible, replace the trim cover. The Astro/Safari van will also have this material on the door trim. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Adjuster Track Cover Replacement - Front Seat Cover: Service and Repair Seat Adjuster Track Cover Replacement - Front REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Unsnap the front tabs, then the rear tabs of the track cover. 3. Remove the track cover from the vehicle. INSTALLATION PROCEDURE 1. Install the track cover on the seat. 2. Snap on the rear tabs, then the front tabs of the track cover. 3. Install the seat in the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Adjuster Track Cover Replacement - Front > Page 13891 Seat Cover: Service and Repair Seat Back Cover and Pad Replacement - Rear REMOVAL PROCEDURE 1. Remove the rear seat from the vehicle. 2. Remove the seat back folding cover, if necessary. 3. Remove the armrest from the seat back, if equipped. 4. Remove the head restraints (1) from the seat back. 5. Remove the seat back plastic cover (10) from the seat back frame, if equipped. 6. Release the J-clips from the seat back cover. 7. Release the hook, and the loop strips retaining the seat back cover (2) to the foam pad (12). 8. In order to ease removal, place a piece of cardboard between the seat back cover and the foam pad. 9. Working from side to side, carefully lift the seat back cover from the foam pad. INSTALLATION PROCEDURE 1. Working from side to side, carefully install the seat back cover over the foam pad. 2. Remove the cardboard from between the seat back cover and the foam pad. 3. Engage the hook, and the loop strips that retain the seat back cover (2). 4. Engage the J-clips that retain the seat back cover. 5. Install the seat back plastic cover (10) to the seat back frame, if equipped. 6. Install the head restraints (1) to the seat back. 7. Install the armrest to the seat back, if removed. 8. Install the seat back folding cover, if removed. 9. Install the rear seat to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Adjuster Track Cover Replacement - Front > Page 13892 Seat Cover: Service and Repair Seat Back Cover Replacement - Rear Folding TOOLS REQUIRED J 34940 Rivet Gun REMOVAL PROCEDURE 1. Fold the seat forward. 2. Remove the rivets using a small bit drill. 3. Remove the rear folding seat panel. INSTALLATION PROCEDURE 1. Install the rear folding seat panel. 2. Install new rivets. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Adjuster Track Cover Replacement - Front > Page 13893 Seat Cover: Service and Repair Seat Cushion Cover and Pad Replacement - Rear REMOVAL PROCEDURE 1. Remove the rear passenger seat from the vehicle. 2. Remove the rear passenger seat riser. 3. Remove the seat cushion plastic cover from the seat cushion frame. 4. Remove the hog rings and/or the J-clips from the rear edge of the seat cushion cover (3). 5. Disconnect the rear heater connector, if equipped. 6. Remove the seat belt buckles, if required. 7. Remove all of the remaining hog rings, and/or the J-clips that are retaining the seat cushion cover (3) to the seat cushion frame (8). 8. Release the hook, and the loop-strips that are retaining the seat cushion cover to the foam pad (4). 9. Remove the center screw retaining the latch cover. 10. Remove the seat cushion cover from the foam pad. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Adjuster Track Cover Replacement - Front > Page 13894 1. Install the seat cushion cover to the foam pad. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the center screw retaining the latch cover. Tighten Tighten the screw to 2 N.m (18 lb in). 3. Engage the hook, and the loop-strips that are retaining the seat cushion cover (3) to the foam pad (4). 4. Install the seat buckles, if removed. 5. Connect the rear heater connector, if equipped. 6. Install the hog rings, and/or the J-clips in order to retain the seat cushion cover to the seat cushion frame (8). 7. Install the seat cushion plastic cover to the seat cushion frame. 8. Install the rear passenger seat risers. 9. Install the rear passenger seat to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Adjuster Track Cover Replacement - Front > Page 13895 Seat Cover: Service and Repair Seat Cushion Trim Cover and Pad Replacement REMOVAL PROCEDURE 1. Remove the seat trim panel. 2. Remove the outboard seat belt anchor nut. Pull the belt through the seat cushion. 3. Remove the front nuts (2) on the underside of the seat cushion. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Adjuster Track Cover Replacement - Front > Page 13896 4. Unsnap the lumbar cable (6) (disconnect the lumbar wire harness if equipped with power lumbar). 5. Disconnect the electrical connectors. 6. Lift the seat cushion up off the rear plastic holders (1) on the underside of the seat cushion, and pull forward. 7. Remove the seat switch bezel. 8. Remove the lumbar actuator (5). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Adjuster Track Cover Replacement - Front > Page 13897 9. Unclip the seat trim cover from the seat cushion frame. 10. Using a side motion, carefully separate the seat cushion trim cover from the seat cushion pad. 11. Remove the pad from the seat cushion frame. 12. Remove the seat cushion heater element, if equipped. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Adjuster Track Cover Replacement - Front > Page 13898 1. Install the seat cushion heater element, if equipped. 2. Install the seat cushion pad to the seat cushion frame. 3. Using a side motion, carefully pull the seat cushion cover onto the frame pad. 4. Attach the seat trim cover to the seat cushion frame. 5. Install the lumbar actuator (5). 6. Install the seat switch bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Adjuster Track Cover Replacement - Front > Page 13899 7. Place the cushion on the rear plastic holders (1) on the underside of the seat cushion, and push rearward. 8. Connect the lumbar cable to the underside of the seat cushion (6). Connect the lumbar wire harness (if equipped with power lumbar). 9. Connect the electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Adjuster Track Cover Replacement - Front > Page 13900 10. Install the front nuts (2) onto the studs on the underside of the cushion. Tighten Tighten the nuts to 21 N.m (15 lb ft). 11. Feed the seat belt through the seat cushion. 12. Install the outboard seal belt anchor nut. Tighten Tighten the nut to 53 N.m (39 lb ft). 13. Install the seat trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Locations Seat Cushion: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Locations > Page 13904 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Locations > Page 13905 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover and Pad Replacement - Rear Seat Cushion: Service and Repair Seat Cushion Cover and Pad Replacement - Rear Seat Cushion Cover and Pad Replacement - Rear Removal Procedure 1. Remove the rear passenger seat from the vehicle.. 2. Remove the rear passenger seat riser. 3. Remove the seat cushion plastic cover from the seat cushion frame. 4. Remove the hog rings and/or the J-clips from the rear edge of the seat cushion cover (3). 5. Disconnect the rear heater connector, if equipped. 6. Remove the seat belt buckles, if required. 7. Remove all of the remaining hog rings, and/or the J-clips that are retaining the seat cushion cover (3) to the seat cushion frame (8). 8. Release the hook, and the loop-strips that are retaining the seat cushion cover to the foam pad (4). 9. Remove the center screw retaining the latch cover. 10. Remove the seat cushion cover from the foam pad. Installation Procedure 1. Install the seat cushion cover to the foam pad. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the center screw retaining the latch cover. Tighten the screw to 2 N.m (18 lb in). 3. Engage the hook, and the loop-strips that are retaining the seat cushion cover (3) to the foam pad (4). 4. Install the seat buckles, if removed. 5. Connect the rear heater connector, if equipped. 6. Install the hog rings, and/or the J-clips in order to retain the seat cushion cover to the seat cushion frame (8). 7. Install the seat cushion plastic cover to the seat cushion frame. 8. Install the rear passenger seat risers. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover and Pad Replacement - Rear > Page 13908 9. Install the rear passenger seat to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover and Pad Replacement - Rear > Page 13909 Seat Cushion: Service and Repair Seat Cushion Frame Replacement - Front Seat Cushion Frame Replacement - Front Removal Procedure 1. Remove the seat trim panel. 2. Remove the seat cushion trim cover and pad. 3. Remove the following components from the seat cushion frame: * The frame springs (1) * The frame suspension (2) * The plastic retainers (3) 4. Remove the seat cushion frame from the vehicle. Installation Procedure 1. Install the following components to the seat cushion frame: * The plastic retainers (3) * The frame suspension (2) * The frame springs (1) 2. Install the seat cushion trim cover and pad. 3. Install the seat trim panel. 4. Calibrate the Inflatable Restraint Passenger Presence System. Refer to in SIR. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover and Pad Replacement - Rear > Page 13910 Seat Cushion: Service and Repair Seat Cushion Frame Replacement - Rear (60/40 Split - 50/50 Split) Seat Cushion Frame Replacement - Rear (60/40 Split - 50/50 Split) Removal Procedure 1. Remove the seat cushion trim cover (8) and the pad (7). 2. Remove the bolts from the hinge assembly, if equipped with folding seats. 3. Remove the seat cushion frame (5). Installation Procedure 1. Install the seat cushion frame (5). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the hinge assembly, if removed. Tighten to 7 N.m (61 lb in). 3. Install the seat cushion trim cover (8) and the pad (7). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover and Pad Replacement - Rear > Page 13911 Seat Cushion: Service and Repair Seat Cushion Trim Cover and Pad Replacement Seat Cushion Trim Cover and Pad Replacement Removal Procedure 1. Remove the seat trim panel. 2. Remove the outboard seat belt anchor nut. Pull the belt through the seat cushion. 3. Remove the front nuts (2) on the underside of the seat cushion. 4. Unsnap the lumbar cable (6) (disconnect the lumbar wire harness if equipped with power lumbar). 5. Disconnect the electrical connectors. 6. Lift the seat cushion up off the rear plastic holders (1) on the underside of the seat cushion, and pull forward. 7. Remove the seat switch bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover and Pad Replacement - Rear > Page 13912 8. Remove the lumbar actuator (5). 9. Unclip the seat trim cover from the seat cushion frame. 10. Using a side motion, carefully separate the seat cushion trim cover from the seat cushion pad. 11. Remove the pad from the seat cushion frame. 12. Remove the seat cushion heater element, if equipped. Installation Procedure 1. Install the seat cushion heater element, if equipped. 2. Install the seat cushion pad to the seat cushion frame. 3. Using a side motion, carefully pull the seat cushion cover onto the frame pad. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover and Pad Replacement - Rear > Page 13913 4. Attach the seat trim cover to the seat cushion frame. 5. Install the lumbar actuator (5). 6. Install the seat switch bezel. 7. Place the cushion on the rear plastic holders (1) on the underside of the seat cushion, and push rearward. 8. Connect the lumbar cable to the underside of the seat cushion (6). Connect the lumbar wire harness (if equipped with power lumbar). 9. Connect the electrical connectors. Notice: Refer to Fastener Notice in Service Precautions. 10. Install the front nuts (2) onto the studs on the underside of the cushion. Tighten the nuts to 21 N.m (15 lb ft). 11. Feed the seat belt through the seat cushion. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover and Pad Replacement - Rear > Page 13914 12. Install the outboard seat belt anchor nut. Tighten the nut to 53 N.m (39 lb ft). 13. Install the seat trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Back Heater Element Replacement - Front Seat Heater: Service and Repair Seat Back Heater Element Replacement - Front REMOVAL PROCEDURE For the Escalade model, the seat back heater is sewn into the seat back cover. Refer to Seat Back Cover and Pad Replacement - Front in order to replace the seat back cover. For all other models, refer to the procedure below. 1. Remove the seat from the vehicle. 2. Remove the seat back trim cover. 3. Peel the seat back heater off the foam pad. 4. Disconnect the seat back heater harness. INSTALLATION PROCEDURE 1. Connect the seat back heater harness. 2. Install the seat back heater. 3. Install the seat back trim cover. 4. Install the seat in the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Back Heater Element Replacement - Front > Page 13919 Seat Heater: Service and Repair Seat Cushion Heater Element Replacement - Front REMOVAL PROCEDURE 1. Remove the seat trim panel. 2. Remove the seat cushion trim cover. 3. Peel the seat cushion heater off of the pad. 4. Disconnect the seat cushion heater wiring harness. INSTALLATION PROCEDURE 1. Connect the cushion heater wiring harness. 2. Install the seat cushion heater. 3. Install the seat cushion trim cover. 4. Install the seat trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Back Heater Element Replacement - Front > Page 13920 Seat Heater: Service and Repair Seat Cushion Heater Replacement - Rear REMOVAL PROCEDURE 1. Remove the seat cushion trim cover. 2. Peel the seat cushion heater off of the pad. 3. Disconnect the seat cushion heater wiring harness. INSTALLATION PROCEDURE 1. Connect the cushion heater wiring harness. 2. Install the seat cushion heater. 3. Install the seat cushion trim cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Page 13924 Seat Heater Control Module: Diagrams Heated Seat Module - LR Heated Seat Module - RR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 13928 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 13929 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 13930 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 13931 Seat Heater Switch: Diagrams Heated Seat Switch - Front Passenger Heated Seat Switch - LR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 13932 Heated Seat Switch - RR Memory/Heated Seat Switch - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Replacement - Front Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Front Heated Seat Switch Replacement - Front Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the retaining clips for the front seat heater switch in order to remove the switch. 4. Remove the front seat heater switch. Installation Procedure 1. Install the front seat heater switch to the front trim panel by pressing the switch into place until the switch is completely seated. 2. Connect the electrical connector to the front seat heater switch. 3. Install the front trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Replacement - Front > Page 13935 Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Rear Heated Seat Switch Replacement - Rear Removal Procedure 1. Remove the center console end panel. 2. Disconnect the electrical connector. 3. Remove the seat heater switch retaining screws. 4. Remove the switch from the vehicle. Installation Procedure 1. Install the switch to the console panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screw. Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector. 4. Install the center console end panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair Seat Latch: Service and Repair Seat Back Latch Replacement - Rear Removal Procedure 1. Remove the rear seat from the vehicle. 2. Remove the armrest, if equipped. 3. Remove the seat back cover. 4. Remove the bolts (1,2) that retain the latch assembly to the seat frame. 5. Remove the screw (3) that retains the latch assembly to the seat frame. 6. Unsnap the recliner cables from the folding mechanism. 7. Remove the seat back latch assembly from the seat frame. 8. Remove the spacer (2) from the latch assembly, if equipped. 9. Remove the seat belt guide (1) from the latch assembly, if equipped. Installation Procedure 1. Install the seat belt guide (1) to the latch assembly, if removed. 2. Install the spacer (2) to the latch assembly, if removed. 3. Install the seat back latch assembly to the seat frame. 4. Attach the recliner cables to the folding mechanism. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 13939 5. Install the bolts (1,2) that retain the latch assembly to the seat frame. Tighten the bolts to 45 N.m (33 lb ft). 6. Install the screw (3) that retains the latch assembly to the seat frame. Tighten the screw to 25 N.m (18 lb ft). 7. Install the seat back cover. 8. Install the armrest, if equipped. 9. Install the rear seat to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement Seat Track: All Technical Service Bulletins Interior - Loose/Unwanted Seat Movement Bulletin No.: 05-08-50-012A Date: July 24, 2006 TECHNICAL Subject: Unwanted/Loose Seat Movement (Apply Adhesive and Install New Bolts in Seat Mounting Rails) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac ESV 1999-2007 Chevrolet Silverado Pickup Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Pickup Models (Classic) 2000-2006 GMC Yukon, Yukon XL 2003-2006 HUMMER H2 with Power Driver Front Seat Power Adjuster (RPO AG1) and/or Passenger Seat Power Adjuster (RPO AG2) Supercede: This bulletin is being revised to add model years and additional Warranty Information. Please discard Corporate Bulletin Number 05-08-50-012 (Section 08 - Body and Accessories). Condition Some customers may comment on unwanted seat movement in the front power bucket seat (driver or passenger) during fast acceleration or hard braking. A metal to metal clicking noise is often heard at seat "stops." Cause The threads of the two zinc nut retainers (one on each side of the seat adjuster) may creep over time, causing a loss of self-rolling screw clamp load and ultimately causes relative rail and vehicle seat motion. Correction Apply adhesive and install new bolts in seat mounting rails using the following procedure. 1. Remove the front seat and invert onto a flat surface covered with a clean, non-scratch material (soft cloth or similar). Refer to the applicable Seats sub-section in SI. Adjust so that the seat mounting rails are at 45 degrees. 2. Remove the upper M8 mounting bolt from one rail and discard. Leave the other bolt intact as this will hold the track in place while working. Wipe the bolt hole area with a clean rag. Important: Only use the adhesive provided in the repair kit. Do not substitute with other adhesives. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement > Page 13948 3. Take one of the adhesive sachets and carefully cut the flag tip off the notched end spout in line with the notch. 4. While holding the sachet vertical, slowly dribble the adhesive into the edge of the bolt hole as shown, ensuring that the adhesive flows into the joint between the seat rail and the zinc block. DO NOT pour the adhesive down the center of the hole. The object is to let the adhesive "wick" between the zinc block and the seat rail in order to bond the two pieces together. Important: If the bolt thread strips or the proper torque cannot be achieved, then the entire seat adjuster mechanism must be replaced. 5. Replace the previous bolt with a new M8 bolt (1) (included) and install using a "click torque wrench" preset to 9 N.m (79 lb in). 6. Remove the second M8 mounting bolt from the rail and discard. 7. Repeat steps 2 through 5 for the second bolt. 8. Repeat steps 2 through 6 for the opposite mounting rail. 9. Before installing the seat into the vehicle, verify that the seat will function correctly and does not make any unusual noises during forward and rearward travel motion. 10. Install the seat. Refer to the applicable Seats sub-section of SI. 11. While sitting in the seat, verify seat function and listen for any unusual noises. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement > Page 13949 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement Seat Track: Customer Interest Interior - Loose/Unwanted Seat Movement Bulletin No.: 05-08-50-012A Date: July 24, 2006 TECHNICAL Subject: Unwanted/Loose Seat Movement (Apply Adhesive and Install New Bolts in Seat Mounting Rails) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac ESV 1999-2007 Chevrolet Silverado Pickup Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Pickup Models (Classic) 2000-2006 GMC Yukon, Yukon XL 2003-2006 HUMMER H2 with Power Driver Front Seat Power Adjuster (RPO AG1) and/or Passenger Seat Power Adjuster (RPO AG2) Supercede: This bulletin is being revised to add model years and additional Warranty Information. Please discard Corporate Bulletin Number 05-08-50-012 (Section 08 - Body and Accessories). Condition Some customers may comment on unwanted seat movement in the front power bucket seat (driver or passenger) during fast acceleration or hard braking. A metal to metal clicking noise is often heard at seat "stops." Cause The threads of the two zinc nut retainers (one on each side of the seat adjuster) may creep over time, causing a loss of self-rolling screw clamp load and ultimately causes relative rail and vehicle seat motion. Correction Apply adhesive and install new bolts in seat mounting rails using the following procedure. 1. Remove the front seat and invert onto a flat surface covered with a clean, non-scratch material (soft cloth or similar). Refer to the applicable Seats sub-section in SI. Adjust so that the seat mounting rails are at 45 degrees. 2. Remove the upper M8 mounting bolt from one rail and discard. Leave the other bolt intact as this will hold the track in place while working. Wipe the bolt hole area with a clean rag. Important: Only use the adhesive provided in the repair kit. Do not substitute with other adhesives. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement > Page 13955 3. Take one of the adhesive sachets and carefully cut the flag tip off the notched end spout in line with the notch. 4. While holding the sachet vertical, slowly dribble the adhesive into the edge of the bolt hole as shown, ensuring that the adhesive flows into the joint between the seat rail and the zinc block. DO NOT pour the adhesive down the center of the hole. The object is to let the adhesive "wick" between the zinc block and the seat rail in order to bond the two pieces together. Important: If the bolt thread strips or the proper torque cannot be achieved, then the entire seat adjuster mechanism must be replaced. 5. Replace the previous bolt with a new M8 bolt (1) (included) and install using a "click torque wrench" preset to 9 N.m (79 lb in). 6. Remove the second M8 mounting bolt from the rail and discard. 7. Repeat steps 2 through 5 for the second bolt. 8. Repeat steps 2 through 6 for the opposite mounting rail. 9. Before installing the seat into the vehicle, verify that the seat will function correctly and does not make any unusual noises during forward and rearward travel motion. 10. Install the seat. Refer to the applicable Seats sub-section of SI. 11. While sitting in the seat, verify seat function and listen for any unusual noises. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement > Page 13956 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Underhood Lamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13963 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13964 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13965 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13966 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13967 Underhood Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13968 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13969 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13970 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13971 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13972 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13973 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13974 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13975 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13976 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13977 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13978 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13979 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13980 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13981 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13982 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13983 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13984 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13985 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13986 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13987 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13988 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13989 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13990 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13991 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 13992 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch - Driver/Front Passenger Door Lock Switch - Driver/Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch - Driver/Front Passenger > Page 13997 Window/Door Lock Switch - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Door Lock Switch Replacement - Front Power Door Lock Switch: Service and Repair Power Door Lock Switch Replacement - Front REMOVAL PROCEDURE 1. Remove the power accessory switch panel. 2. Disconnect the electrical connector from the door lock switch. 3. Remove the screws from the door lock switch. 4. Remove the power window and door lock switch from the switch panel. INSTALLATION PROCEDURE 1. Install the power door lock and power window switch assembly to the switch panel, sliding the front tabs in first. Rock the switch down in order to seat the door lock switch completely. 2. Install the screws to the door lock switch. 3. Connect the electrical connector to the door lock switch. 4. Install the power accessory switch plate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Door Lock Switch Replacement - Front > Page 14000 Power Door Lock Switch: Service and Repair Power Door Lock Switch Replacement - Rear REMOVAL PROCEDURE 1. Remove the upper garnish molding. 2. Remove the D-Pillar molding. 3. Disconnect the electrical connectors. 4. Push on the tab (2) in order to remove the switch from the D-Pillar molding. 5. Insert a small screwdriver between the tab (1) in order to pry out the switch from the case. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Door Lock Switch Replacement - Front > Page 14001 1. Install the switch into the case by pushing until the tab (1) locks into place. 2. Install the switch assembly into the D-Pillar molding. 3. Connect the electrical connectors. 4. Install the D-Pillar molding to vehicle. 5. Install the upper garnish molding to vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch Replacement Power Mirror Switch: Service and Repair Power Mirror Switch Replacement REMOVAL PROCEDURE 1. Remove the power accessory switch panel. 2. Remove the power mirror switch from the accessory switch panel using a flat-bladed tool in order to release the retainer tabs. INSTALLATION PROCEDURE 1. Install the power mirror switch, pressing the switch into place until fully seated. 2. Install the power accessory switch panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch Replacement > Page 14006 Power Mirror Switch: Service and Repair Power Folding Outside Mirror Switch Replacement REMOVAL PROCEDURE 1. Remove the instrument panel (IP) bezel. 2. Release the plastic retaining clips using a flat-bladed tool in order to remove the power folding mirror switch. 3. Disconnect the electrical connectors. 4. Remove the power folding mirror switch from the IP accessory housing. INSTALLATION PROCEDURE 1. Connect the electrical connectors. 2. Install the power folding mirror switch to the IP accessory housing. 3. Push in the power folding mirror switch until the switch snaps into position. 4. Install the power accessory switch panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Recliner Motor Position Sensor - Driver Seat Recliner Motor Position Sensor - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Recliner Motor Position Sensor - Driver > Page 14011 Seat Front Vertical Motor Position Sensor - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Recliner Motor Position Sensor - Driver > Page 14012 Seat Horizontal Motor Position Sensor - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Recliner Motor Position Sensor - Driver > Page 14013 Seat Rear Vertical Motor Position Sensor - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: Customer Interest Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing > Page 14022 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: All Technical Service Bulletins Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing > Page 14028 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch Power Seat Switch: Diagrams Lumbar/Bolster Switch Lumbar/Bolster Switch - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch > Page 14031 Lumbar/Bolster Switch - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch > Page 14032 Power Seat Switch: Diagrams Seat Adjuster Switch Seat Adjuster Switch - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch > Page 14033 Seat Adjuster Switch - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch > Page 14034 Seat Adjuster Switch - Driver - Full Feature Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Lumbar/Bolster Switch > Page 14035 Seat Adjuster Switch - Front Passenger - Full Feature Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Switch Bezel Replacement Power Seat Switch: Service and Repair Seat Switch Bezel Replacement Seat Switch Bezel Replacement Removal Procedure 1. Remove the lumbar knob, if equipped. 2. Remove the screws retaining the power seat switch bezel. 3. Disconnect the electrical connectors. 4. Remove the lumbar support switch. 5. Remove the power seat adjuster switch assembly. Installation Procedure 1. Install the power seat adjuster switch assembly to the seat switch bezel. 2. Install the lumbar support switch to the seat switch bezel. 3. Connect the electrical connectors. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the screws retaining the power seat switch bezel. Tighten the screws to 2 N.m (18 lb in). 5. Install the lumbar knob, if equipped. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Switch Bezel Replacement > Page 14038 Power Seat Switch: Service and Repair Seat Switch Replacement - Power Seat Switch Replacement - Power Removal Procedure 1. Remove the lumbar knob, if equipped. 2. Remove the power seat switch bezel from the seat. 3. Remove the power seat switch to bezel screws. 4. Remove the power seat switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten the screws to 2 N.m (18 lb in). 2. Install the power seat switch bezel to the seat. 3. Install the lumbar knob, if equipped. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Switch Bezel Replacement > Page 14039 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Removal Procedure 1. Remove the power seat switch bezel containing the lumbar switch (1) from the seat. 2. Remove the lumbar switch screws from the power seat switch bezel. 3. Remove the lumbar switch. Installation Procedure 1. Install the lumbar switch to the power seat switch bezel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the lumbar switch screws. Tighten the screws to 2 N.m (18 lb in). 3. Install the power seat switch bezel (1) to the seat. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams Liftgate/Liftglass Ajar Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 14046 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 14047 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 14048 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 14049 Seat Heater Switch: Diagrams Heated Seat Switch - Front Passenger Heated Seat Switch - LR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 14050 Heated Seat Switch - RR Memory/Heated Seat Switch - Driver Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Replacement - Front Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Front Heated Seat Switch Replacement - Front Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the retaining clips for the front seat heater switch in order to remove the switch. 4. Remove the front seat heater switch. Installation Procedure 1. Install the front seat heater switch to the front trim panel by pressing the switch into place until the switch is completely seated. 2. Connect the electrical connector to the front seat heater switch. 3. Install the front trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Replacement - Front > Page 14053 Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Rear Heated Seat Switch Replacement - Rear Removal Procedure 1. Remove the center console end panel. 2. Disconnect the electrical connector. 3. Remove the seat heater switch retaining screws. 4. Remove the switch from the vehicle. Installation Procedure 1. Install the switch to the console panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screw. Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector. 4. Install the center console end panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Sunroof Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 14057 Sunroof / Moonroof Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the roof console assembly. 2. Disconnect the electrical connector. 3. Remove the switch by un-snapping from roof console assembly. INSTALLATION PROCEDURE 1. Install the switch to roof console assembly by snapping into place. 2. Connect the electrical connector. 3. Install the roof console assembly. 4. Synchronize the sunroof motor. Refer to Sunroof Motor Synchronization. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Trunk / Liftgate Switch: Diagrams Cargo Door Ajar Switch Cargo Door Key Switch - Security - RH Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 14061 Liftgate Key Switch - Security Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Spare Tire Carrier > Component Information > Technical Service Bulletins > Spare Tire - Lowering Information Spare Tire Carrier: Technical Service Bulletins Spare Tire - Lowering Information File In Section: 03 - Suspension Bulletin No.: 01-03-10-007 Date: October, 2001 INFORMATION Subject: Information on Lowering Spare Tires Stored Under Vehicle Models: 2002 and Prior Light Duty Trucks with Spare Tire Stored Under Vehicle Spare tires stored under the vehicle are lowered and raised using a vehicle mounted hoist. Operating the hoist at high speed can cause the hoist cable to bind which could make the hoist inoperative. The use of air tools to lower or raise the hoist results in high operating speeds. Important: The hoist should be only lowered and raised by hand using the tools supplied with the vehicle. DO NOT USE AIR TOOLS TO OPERATE THE HOIST. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Spare Tire Carrier > Component Information > Technical Service Bulletins > Page 14066 Spare Tire Carrier: Service and Repair Tire Hoist and Shaft Replacement Removal Procedure 1. Remove the spare wheel stowage lock cylinder. 2. Remove the spare tire from the hoist. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the spare tire wheel hoist guide retaining clips from the bumper (1). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Spare Tire Carrier > Component Information > Technical Service Bulletins > Page 14067 5. Remove the spare wheel hoist shaft guide (2) from the bumper. 6. Remove the spare wheel hoist shaft guide from the spare wheel hoist. 7. Remove the bolt. 8. Remove the hoist from the bracket. Installation Procedure 1. Install the hoist to the crossmember. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Spare Tire Carrier > Component Information > Technical Service Bulletins > Page 14068 2. Install the bolt. Tighten the bolt to 40 Nm (30 ft. lbs.). 3. Install the spare wheel hoist shaft guide from the spare wheel hoist. 4. Install the spare wheel hoist shaft guide (2) to the bumper. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Spare Tire Carrier > Component Information > Technical Service Bulletins > Page 14069 5. Install the spare wheel hoist shaft guide retaining clips to the bumper (1). 6. Install the spare tire to the hoist. 7. Remove the safety stands. 8. Lower the vehicle. 9. Install the spare wheel stowage lock cylinder. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair Spoiler: Service and Repair Spoiler Replacement - Rear Tools Required J 25070 Heat Gun Removal Procedure Important: Be careful not to scratch or chip the paint. 1. Heat the spoiler using a heat gun. Hold the heat gun approximately 152 mm (6 in) from the surface. Apply heat using a circular motion for about 30 seconds. 2. Starting from one end of the spoiler, peel off the Endgate surface using a flat-bladed tool. 3. Remove all adhesive from the body panel using a 3M(TM) stripe off wheel # 07498 or equivalent. Installation Procedure Important: Apply the molding in an environment free of dust and dirt. Dust and dirt could come in contact with the adhesive surface and prevent proper adhesion. 1. Clean the area where the replacement molding is to be mounted. Use a suitable solvent such as flash naphtha or a mixture of 50 percent isopropyl alcohol and 50 percent water. 2. Dry the area thoroughly. 3. Warm the body panel to a temperature range of 16-41°C (60-105°F) with a heat lamp or heat gun. 4. Ensure the spoiler is at a minimum temperature of 16°C (60°F). If the temperature of the molding is below 16°C (60°F), warm up spoiler with a heat lamp or heat gun. Important: Do not touch the adhesive surface when the tape is removed. 5. Remove the protective tape. 6. Without allowing the adhesive surface to touch the endgate, ensure the molding is aligned. 7. Install as shown in side view. 8. Press on the molding in order to install to the body. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair Tailgate Latch: Service and Repair Latch Replacement - End Gate Removal Procedure 1. Lower the endgate. 2. Loosen the handle bolts. 3. Raise the endgate. 4. Remove the handle bezel by prying gently on the upper retainer tabs. 5. Disengage the linkage rods (1). 6. Lower and support the endgate. 7. Remove the cables from the side panel cable retainer bolts. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Page 14078 8. Remove the bolt holding the latch assembly. 9. Disengage the linkage rod from the latch assembly. 10. Remove the latch assembly from the endgate. Installation Procedure 1. Engage the linkage rod to the latch assembly. 2. Install the latch assembly to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the latch assembly bolts. Tighten the bolts to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Page 14079 4. Connect the cables on each side of the endgate to the side panel cable retainer bolts. 5. Engage the linkage rods (1). 6. Raise the endgate. 7. Install the endgate handle bezel. 8. Tighten the handle bolts. Tighten the bolts to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Service and Repair Tailgate Lock Cylinder: Service and Repair Lock Cylinder Replacement - End Gate (Avalanche) Removal Procedure 1. Remove the endgate handle bezel. 2. Release the tabs (2) retaining the cylinder to the bezel with a flat bladed tool. 3. Remove the lock cylinder (1). Installation Procedure 1. Install the lock cylinder into the cylinder sleeve (3). Ensure that the cylinder is fully seated into the retaining tabs (2). 2. Install handle bezel to the endgate. Line up the lock cylinder arm (4) with the opening in the handle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Assist Handle Replacement - Endgate (Avalanche) Tailgate Release Handle: Service and Repair Assist Handle Replacement - Endgate (Avalanche) Assist Handle Replacement - End Gate (Avalanche) Removal Procedure 1. Open the cargo box stowage lid. 2. Remove the retaining bolts (1) from the assist handle. 3. Remove the assist handle from the endgate. Installation Procedure 1. Install the assist handle to the endgate cap. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (1) to the assist handle in order to attach the assist handle to the endgate cap. Tighten the bolts to 9 N.m (80 lb in). 3. Close the cargo box stowage lid. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Assist Handle Replacement - Endgate (Avalanche) > Page 14087 Tailgate Release Handle: Service and Repair Handle Replacement - End Gate (Avalanche) Handle Replacement - End Gate (Avalanche) Removal Procedure 1. Remove the endgate handle bezel. 2. Release the endgate handle linkage rod retainers. Refer to End Gate Adjustment. 3. Remove the 3 bolts (1) that retain the handle to the endgate. 4. Remove the endgate spoiler. 5. Remove the handle. Installation Procedure 1. Set the handle in position in the endgate. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts (1) that retain the handle to the endgate. Tighten the bolts to 25 N.m(18 lb ft). 3. Install the endgate spoiler. 4. Reattach the handle linkage rods and adjust the endgate latch. Refer to End Gate Adjustment. 5. Reattach the endgate handle bezel. Refer to End Gate Adjustment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Service and Repair > Lock Striker Replacement - End Gate Tailgate Striker: Service and Repair Lock Striker Replacement - End Gate REMOVAL PROCEDURE 1. Remove the lower striker bolt. 2. Remove the striker. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice Service Precautions. 1. Install the striker. Tighten Tighten the bolts to 22 N.m (15 lb ft). 2. Install the trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Service and Repair > Lock Striker Replacement - End Gate > Page 14092 Tailgate Striker: Service and Repair Lock Striker Replacement - End Gate (Tahoe/Yukon Adjustment) Lock Striker Replacement - End Gate (Tahoe/Yukon Adjustment) 1. Remove the rear sill plate trim panel. 2. Loosen the striker bolts. 3. Move the assembly, forward or backward, in order to obtain the proper close of the liftgate. Notice: Refer to Fastener Notice in Service Precautions. 4. Ensure that the endgate seals completely with the minimum closing effort. Tighten the striker assembly to 25 N.m (18 lb ft). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Service and Repair > Lock Striker Replacement - End Gate > Page 14093 Tailgate Striker: Service and Repair Lock Striker Replacement - End Gate (Tahoe/Yukon) Lock Striker Replacement - End Gate (Tahoe/Yukon) Removal Procedure 1. Remove the lower striker bolt. 2. Remove the striker. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the striker. Tighten the bolts to 22 N.m (16 lb ft). 2. Install the trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Weatherstrip > Component Information > Service and Repair Tailgate Weatherstrip: Service and Repair Weatherstrip Replacement - End Gate (Avalanche) Removal Procedure 1. Open the endgate. 2. Starting from either side, pull on weatherstrip in order to remove the weatherstrip. Installation Procedure Important: Prior to installing the weatherstrip, ensure that the area is clean and free of foreign material. 1. Starting from either side, install the weatherstrip by inserting the groove to the endgate opening flange. 2. Close the endgate. 3. Inspect for interference. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup Truck Bed: Service and Repair Cargo Box Front Gutter Side Drain Replacement - A Cup Cargo Box Front Gutter Side Drain Replacement - A Cup Removal Procedure 1. Lower the mid gate. 2. Remove the compartment cover. 3. Remover the front cargo box side drain cup retainer. 4. Pull the drain cup away and forward to disengage the cup from the cargo box side. Installation Procedure 1. Align the cup to engage the drain gutter. 2. Insert the drain cup into the cargo box side. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup > Page 14101 3. Install the front cargo box side drain cup retainer. 4. Close the mid gate. 5. Install the compartment cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup > Page 14102 Truck Bed: Service and Repair Cargo Box Gutter Side Drain Assembly Replacement Cargo Box Gutter Side Drain Assembly Replacement Removal Procedure 1. Lower the end gate. 2. Remove the rear compartment cover assembly. 3. Remove the rear cargo box side drain cups. 4. Remove the front cargo box side drain cups. 5. Pull downward to disengage the drain gutter retainers from the cargo stowage box. Installation Procedure 1. Install the drain gutter retainers by pushing the drain gutter upward into the retainer holes. 2. Install the rear cargo box side drain cup. 3. Install the front cargo box side drain cup. 4. Install the rear compartment cover assembly. 5. Close the end gate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup > Page 14103 Truck Bed: Service and Repair Cargo Box Rear Gutter Side Drain Replacement - B Cup Cargo Box Rear Gutter Side Drain Replacement - B Cup Removal Procedure 1. Lower the end gate. 2. Remove the rear cargo box side drain cup retainers. 3. Pull the drain cup away and rearward to disengage the cup from the cargo box side. Installation Procedure 1. Align the cup to engage the drain gutter. 2. Insert the drain cup into the cargo box side. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup > Page 14104 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the rear cargo box side drain cup retainers. 4. Tighten the fastener. Tighten the fastener to 1.2 N.m +2 or -2 (10 in lbs). 5. Close the mid gate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup > Page 14105 Truck Bed: Service and Repair Cargo Cover Compression Latch Replacement Cargo Cover Compression Latch Replacement Removal Procedure 1. Lower the end gate. 2. Remove the cargo cover assembly from the vehicle. 3. Remove the latch fastener. 4. Remove the latch from the cargo cover. Installation Procedure 1. Install the latch to the cargo cover. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the fasteners to the latch. Tighten the fasteners to 6 N.m (53 lb in). 3. Install the rear compartment cover assembly to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup > Page 14106 Truck Bed: Service and Repair Cargo Box Front Gutter Side Drain Replacement - A Cup Cargo Box Front Gutter Side Drain Replacement - A Cup Removal Procedure 1. Lower the mid gate. 2. Remove the compartment cover. 3. Remover the front cargo box side drain cup retainer. 4. Pull the drain cup away and forward to disengage the cup from the cargo box side. Installation Procedure 1. Align the cup to engage the drain gutter. 2. Insert the drain cup into the cargo box side. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup > Page 14107 3. Install the front cargo box side drain cup retainer. 4. Close the mid gate. 5. Install the compartment cover. Cargo Box Gutter Side Drain Assembly Replacement Cargo Box Gutter Side Drain Assembly Replacement Removal Procedure 1. Lower the end gate. 2. Remove the rear compartment cover assembly. 3. Remove the rear cargo box side drain cups. 4. Remove the front cargo box side drain cups. 5. Pull downward to disengage the drain gutter retainers from the cargo stowage box. Installation Procedure 1. Install the drain gutter retainers by pushing the drain gutter upward into the retainer holes. 2. Install the rear cargo box side drain cup. 3. Install the front cargo box side drain cup. 4. Install the rear compartment cover assembly. 5. Close the end gate. Cargo Box Rear Gutter Side Drain Replacement - B Cup Cargo Box Rear Gutter Side Drain Replacement - B Cup Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup > Page 14108 Removal Procedure 1. Lower the end gate. 2. Remove the rear cargo box side drain cup retainers. 3. Pull the drain cup away and rearward to disengage the cup from the cargo box side. Installation Procedure 1. Align the cup to engage the drain gutter. 2. Insert the drain cup into the cargo box side. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup > Page 14109 3. Install the rear cargo box side drain cup retainers. 4. Tighten the fastener. Tighten the fastener to 1.2 N.m +2 or -2 (10 in lbs). 5. Close the mid gate. Cargo Cover Compression Latch Replacement Cargo Cover Compression Latch Replacement Removal Procedure 1. Lower the end gate. 2. Remove the cargo cover assembly from the vehicle. 3. Remove the latch fastener. 4. Remove the latch from the cargo cover. Installation Procedure 1. Install the latch to the cargo cover. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the fasteners to the latch. Tighten the fasteners to 6 N.m (53 lb in). 3. Install the rear compartment cover assembly to the vehicle. Deflector Replacement - Body Side Rear Drain Deflector Replacement - Body Side Rear Drain Removal Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup > Page 14110 1. Lower the end gate. 2. Remove the rear compartment cover assembly(s). 3. Remove the rear side drain duct cover by pulling upward. Installation Procedure 1. Install the rear side drain duct cover. 2. Push downward on the rear side drain duct cover to ensure the retainers are seated. 3. Replace the rear compartment assembly(s). 4. Close the end gate. Duct Replacement - Body Side Rear Quarter Drain (Avalanche) Duct Replacement - Body Side Rear Quarter Drain (Avalanche) Removal Procedure 1. Lower the endgate. 2. Remove the rear compartment cover assembly. 3. Remove the assist handle. 4. Remove the rear body side drain deflector. 5. Remove the cargo box stowage lid assembly. 6. Remove the cargo box stowage box. 7. Remove the push-pin retainers from the duct assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup > Page 14111 8. Remove the drain hose and grommet from the inner fender wheelwell. 9. Remove the duct assembly from the vehicle. Installation Procedure 1. Install the duct assembly to the vehicle. 2. Insert the drain hose through the inner fender wheel well and forward of the rear wheel.. 3. Insert the push-pin retainers to the duct assembly. 4. Install the cargo box stowage box. 5. Install the cargo box stowage lid assembly. 6. Install the rear body side drain deflector. 7. Install the assist handle. 8. Install the rear compartment cover assembly. 9. Close the endgate. Grate Replacement - Load Floor Water Management (Avalanche) Grate Replacement - Load Floor Water Management (Avalanche) Removal Procedure 1. Remove the rear compartment cover assembly. 2. Remove the load floor mat from the vehicle. 3. Pull up on the grate panel in order to remove. 4. Remove the bolts from the panel assembly load floor trim. 5. Remove the panel from the vehicle. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup > Page 14112 1. Install the panel assembly - load floor to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts to the load floor trim panel. Tighten the bolts to 4 N.m (35 lb in). 3. Install the load floor mat to the vehicle. 4. Install the rear compartment cover assembly to the vehicle. Panel Replacement - Cargo Box Bridge Side Inner (Avalanche/EXT) Panel Replacement - Cargo Box Bridge Side Inner (Avalanche) Removal Procedure 1. Remove the rear compartment cover assembly. 2. Remove the panel - cargo box bridge center. 3. Remove the retaining screws (1) from the side inner panel. 4. Remove the side inner panel from the vehicle. Installation Procedure 1. Install the inner side panel to the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup > Page 14113 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screws (1) to the inner side panel. Tighten the inner side panel screws to 7 N.m (62 lb in). 3. Install the panel - cargo box bridge center. 4. Install the rear compartment cover assembly. Panel Replacement - Cargo Box Bridge Side Outer (Avalanche/EXT) Panel Replacement - Cargo Box Bridge Side Outer (Avalanche) Removal Procedure 1. Remove the rear compartment cover assembly. 2. Remove the cargo box bridge center panel. 3. Remove the side inner panel. 4. Remove the side outer panel by pulling up in order to release the panel from the fasteners. Installation Procedure 1. Install the side outer panel to the body side outer panel fasteners. 2. Install the side inner panel. 3. Install the cargo box bridge center panel. 4. Install the rear compartment cover assembly. Rear Body Opening Frame Drain Valve Replacement - Front Rear Body Opening Frame Drain Valve Replacement - Front Removal Procedure 1. Lower the mid gate. 2. Remove the rear compartment cover. 3. Remove the cargo load mat. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup > Page 14114 4. Using a trim panel removal tool or a suitable flat bladed tool, carefully pry the drain valve up from the cargo floor. 5. Remove the drain valve from the vehicle. Installation Procedure 1. Align the drain valve into the opening in the floor. 2. Press down on the drain valve to fully seat the valve into the floor. 3. Install the cargo load mat. 4. Install the compartment cover. 5. Close the mid gate. Rear Body Opening Frame Drain Valve Replacement - Rear Rear Body Opening Frame Drain Valve Replacement - Rear Removal Procedure 1. Lower the end gate. 2. Remove the rear cargo compartment cover. 3. Remove the cargo box. 4. Using a trim panel removal tool or a suitable flat bladed tool, carefully pry the drain valve up from the cargo floor. 5. Remove the drain valve from the vehicle. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup > Page 14115 1. Align the drain valve into the opening in the floor. 2. Press down on the drain valve to fully seat the valve into the floor. 3. Install the cargo box. 4. Install the compartment cover. 5. Close the end gate. Rear Body Opening Frame Load Floor Grate Drain Valve Replacement Rear Body Opening Frame Load Floor Grate Drain Valve Replacement Removal Procedure 1. Lower the end gate. 2. Remove the compartment cover. 3. Remove the load floor grate. 4. Using a flat bladed tool or suitable replacement to pry the front drain valve from the floor. 5. Remove the valve from the vehicle. Installation Procedure 1. Install the front drain valve into the floor. 2. Press down on the front drain valve using firm pressure to firmly seat the valve into the floor. 3. Install the load floor grate. 4. Install the compartment covers. 5. Close the end gate. Rear Body Opening Frame Mid-Gate Drain Valve Replacement Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Front Gutter Side Drain Replacement - A Cup > Page 14116 Rear Body Opening Frame Mid-Gate Drain Valve Replacement Removal Procedure 1. Lower the mid gate. 2. Raise the close out panel on the load floor grate and support in the raised position. 3. Using a flat bladed tool or suitable replacement to pry the front drain valve from the floor. 4. Remove the valve from the vehicle. Installation Procedure 1. Install the mid gate drain valve into the floor. 2. Press down on the mid gate drain valve using firm pressure to firmly seat the valve into the floor. 3. Lower the load floor grate close out panel. 4. Close the mid gate. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the wiper arms. 2. Pull up in order to release the outboard air inlet grille panel clips. 3. Remove the attaching clips running along the edges of the center air inlet grille panel. 4. Remove the sheet metal screws on each end of the air inlet grille panel. 5. Disconnect the windshield washer hose from the nozzle underneath the center air inlet grille panel. 6. Remove the air inlet grille panel. Installation Procedure 1. Connect the windshield washer hose to the nozzle under the center air inlet grille panel. 2. Position the air inlet grille panel to the vehicle and attach the clips to the edges of the center air inlet grille panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the sheet metal screws on each end of the air inlet grille panel. Tighten the sheet metal screws to 2 N.m (18 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 14122 4. Align the outboard air inlet grille panel clips and press down in order to install. 5. Install the wiper arms. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door (Door Opening) Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door (Door Opening) Weatherstrip Replacement - Front Door (Door Opening) Removal Procedure 1. Open the door. 2. Remove the sill plate. 3. Remove the hinge pillar trim panel. 4. Remove the windshield pillar molding. 5. Remove the weatherstrip from the rear side door opening. Peel the unit away from channel, pulling the weatherstrip from the pinchweld flange. Installation Procedure 1. Install the weatherstrip from the rear side door opening fully seating the weatherstrip into the channel. 2. Install the windshield pillar molding. 3. Install the hinge pillar trim panel. 4. Install the sill plate. 5. Check door closing effort and seal to door fit. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door (Door Opening) > Page 14128 Front Door Weatherstrip: Service and Repair Sealing Strip Replacement - Front Door WDO Belt Outer - Front REMOVAL PROCEDURE IMPORTANT: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outside mirror. 3. Remove the outer sealing strip from the door, lifting up on the forward end in order to unhook the rear of the strip from the window run channel. INSTALLATION PROCEDURE 1. Hook the rear end of the sealing strip into the window run channel. Lower and press the strip into place. 2. Install the outside mirror. 3. Raise the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door (Door Opening) > Page 14129 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Upper Auxiliary Weatherstrip Replacement - Front Door Upper Auxiliary Removal Procedure 1. Open the door. 2. Pull the roof drip molding from the pinch-weld flange and the windshield molding flange. Installation Procedure 1. Push the roof drip molding over the pinch-weld flange. 2. Close the door. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window Front Door Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Window REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the window. 4. Remove the screws. 5. Pull the weatherstrip from the following locations: ^ The front of the glass run channel ^ The top of the window frame flange ^ The rear of the glass run channel 6. Remove the weatherstrip from the door. INSTALLATION PROCEDURE 1. Install the weatherstrip to the following locations: ^ The front of the glass run channel ^ The top of the window frame flange ^ The rear of the glass run channel NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts. Tighten Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 14134 Tighten the bolts to 6 N.m (53 lb in). 3. Install the window. 4. Install the water deflector. 5. Install the door trim panel. 6. Inspect the operation of the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 14135 Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel REMOVAL PROCEDURE 1. Remove the window. 2. Remove the window glass weatherstrip. 3. Remove the window run channel bolts. 4. Remove the front and the rear window run channels from the door INSTALLATION PROCEDURE 1. Install the front and the rear window run channels to the door. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the front and the rear window run channel bolts. Tighten 2.1. Tighten the front bolt to 9 N.m (80 lb in). 2.2. Tighten the rear bolt to 9 N.m (80 lb in). 3. Install the window glass weatherstrip. 4. Install the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 14136 Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Front Door Window Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the window. 4. Remove the screws. 5. Pull the weatherstrip from the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel 6. Remove the weatherstrip from the door. Installation Procedure 1. Install the weatherstrip to the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts. Tighten the bolts to 6 N.m (53 lb in). 3. Install the window. 4. Install the water deflector. 5. Install the door trim panel. 6. Inspect the operation of the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 14137 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Outer - Front Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outside mirror. 3. Remove the outer sealing strip from the door, lifting up on the forward end in order to unhook the rear of the strip from the window run channel. Installation Procedure 1. Hook the rear end of the sealing strip into the window run channel. Lower and press the strip into place. 2. Install the outside mirror. 3. Raise the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Removal Procedure Pull up on the rear hood seal and remove from the cowl pinch-weld flange. Installation Procedure Align the slot in the rear hood seal with the cowl pinch-weld flange and press into place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door - 1 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door - 1 REMOVAL PROCEDURE 1. Open the rear door. 2. Remove the rear door weatherstrip by pulling the weatherstrip from the track. 3. Release push-in retainers on lower weatherstrip from door. 4. Remove the rear door weatherstrip from the rear door. INSTALLATION PROCEDURE 1. Install the rear door weatherstrip on the rear door by pressing weatherstrip onto the track. 2. Install the rear door weatherstrip, by pressing in on the retainers until each retainer is fully seated. 3. Close the rear door. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door - 1 > Page 14145 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door - 2 TOOLS REQUIRED J 38778 Door Trim Pad Clip Remover REMOVAL PROCEDURE 1. Open the door. 2. Using the J 38778, remove the weatherstrip from the mounting surface. INSTALLATION PROCEDURE IMPORTANT: Apply the weatherstrip in an environment that is free from dust or dirt that could come into contact with the adhesive backing. Foreign material may cause improper adhesion. 1. Install the weatherstrip to the mounting surface by completing the following steps: 1.1. Peel off the backing paper. 1.2. Press the retainers into place. 2. Close the door. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door - 1 > Page 14146 Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip Replacement Weatherstrip Replacement - Rear Door Removal Procedure 1. Open the rear door. 2. Remove the rear door weatherstrip by pulling the weatherstrip from the track. 3. Release push-in retainers on lower weatherstrip from door. 4. Remove the rear door weatherstrip from the rear door. Installation Procedure 1. Install the rear door weatherstrip on the rear door by pressing weatherstrip onto the track. 2. Install the rear door weatherstrip, by pressing in on the retainers until each retainer is fully seated. 3. Close the rear door. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door - 1 > Page 14147 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Window Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. Installation Procedure 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window Rear Door Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Window REMOVAL PROCEDURE 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. INSTALLATION PROCEDURE 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 14152 Rear Door Window Glass Weatherstrip: Service and Repair Sealing Strip Replacement - Rear Door Window Belt Outer REMOVAL PROCEDURE IMPORTANT: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outer sealing strip from the door. INSTALLATION PROCEDURE 1. Align the sealing strip in place. Lower and press the strip into place. 2. Raise the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 14153 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Channel REMOVAL PROCEDURE 1. Remove the window. 2. Remove the window glass weatherstrip. 3. Remove the front window run channel top bolt. 4. Remove the front window run channel from the door. INSTALLATION PROCEDURE 1. Install the front window run channel to the door. 2. Install the front window run channel top bolt. Do not tighten the bolt 3. Install the window glass weatherstrip. 4. Install the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 14154 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. Installation Procedure 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 14155 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Rear Door Window Belt Outer Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outer sealing strip from the door. Installation Procedure 1. Align the sealing strip in place. Lower and press the strip into place. 2. Raise the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Tailgate Weatherstrip > Component Information > Service and Repair Tailgate Weatherstrip: Service and Repair Weatherstrip Replacement - End Gate (Avalanche) Removal Procedure 1. Open the endgate. 2. Starting from either side, pull on weatherstrip in order to remove the weatherstrip. Installation Procedure Important: Prior to installing the weatherstrip, ensure that the area is clean and free of foreign material. 1. Starting from either side, install the weatherstrip by inserting the groove to the endgate opening flange. 2. Close the endgate. 3. Inspect for interference. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Mid Gate - Lower Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Mid Gate - Lower Weatherstrip Replacement - Mid Gate - Lower Removal Procedure 1. Fold down the rear seat. 2. Remove the rear removable glass panel. 3. Remove the midgate. 4. Remove the floor hinge molding. 5. Starting from one end remove the weatherstrip from the vehicle. Installation Procedure Important: To begin the installation of the weatherstrip, ensure the weatherstrip is at a minimum of 21°C (70°F). 1. Starting from one end of the weatherstrip, install the weatherstrip. 2. Ensure the corners of the weatherstrip are fully seated. 3. Install the floor hinge molding. 4. Install the midgate. 5. Close the midgate. 6. Install the rear removable rear glass panel. 7. Inspect the weatherstrip when the midgate is closed and the glass panel installed. 8. Set the rear seat in the upright position. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Mid Gate - Lower > Page 14163 Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Mid Gate - Upper Weatherstrip Replacement - Mid Gate - Upper Removal Procedure 1. Fold down the rear seat. 2. Remove the rear removable glass panel. 3. Remove the midgate. 4. Starting from one end, remove the weatherstrip from the vehicle. Installation Procedure Important: To begin the installation of the weatherstrip, ensure the weatherstrip is at a minimum of 21°C (70°F). 1. Starting from one end of the weatherstrip, install the weatherstrip. 2. Ensure the corners of the weatherstrip are fully seated. 3. Install the midgate. 4. Close the midgate. 5. Install the rear removable rear glass panel. 6. Inspect the weatherstrip when the midgate is closed and the glass panel installed. 7. Set the rear seat in the upright position. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Mid Gate - Lower > Page 14164 Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Lift Gate Weatherstrip Replacement - Lift Gate Removal Procedure 1. Open the liftgate. 2. Remove the weatherstrip molding from the pinch- weld flange: 1. Firmly grip the weatherstrip. 2. Carefully pull the weatherstrip out and away from the vehicle. Installation Procedure 1. Align paint mark on the weather-strip to outer top center of pinch weld flange. 2. Push the weather-strip onto the pinch weld flange, beginning from the top center of the endgate opening. 3. Completely seat the weather-strip around the liftgate opening. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Mid Gate - Lower > Page 14165 Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Compartment Opening Weatherstrip Replacement - Rear Compartment Opening Removal Procedure 1. Open the door(s). 2. Remove 7 bolts retaining weatherstrip assembly to body. Installation Procedure 1. Install the weatherstrip assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install 7 bolts retaining weatherstrip assembly to body. Tighten the bolts to 2 N.m (18 lb in). 3. Close the door(s). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 14170 Cruise Control Module (CCM) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 14171 Cruise Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the bolts that retain the upper fender brace assembly. 2. Remove the upper fender brace assembly. 3. Disconnect the electrical connector at the cruise control module. 4. Remove the nuts retaining the cruise control module to the cowl. 5. Disconnect the cruise control cable from the module. 6. Remove the cruise control module from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 14172 1. Install the cruise control module to the vehicle. 2. Connect the cruise control cable to the cruise control module. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts in order to retain the cruise control module to the cowl. Tighten Tighten the nuts to 9 N.m (8O lb in). 4. Connect the electrical connector at the cruise control module. 5. Install the brace. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 14173 Tighten Tighten the bolts to 9 N.m (80 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair Cruise Control Servo Cable: Service and Repair REMOVAL PROCEDURE IMPORTANT: The cruise control cable does not require mechanical adjusting after replacement. The cruise control module internally adjusts the cable. Refer to Cruise Control Description and Operation (W/ ETC) or Cruise Control Description and Operation (W/O ETC) for complete operational details. 1. Remove the engine sight shield. 2. Disconnect the cruise control cable locator clip from the outboard rectangular hole in the routing bracket at the left front corner of the engine. 3. Disconnect the cruise control cable conduit fitting from the round hole in the engine cable bracket. NOTE: Do not remove the C-clip from the cruise control connector. The C-clip was not designed for removal. Damage may occur when removing. 4. Disconnect the cruise control cable engine-end fitting from the stud on the throttle lever. 5. Disconnect the cruise control cable fitting from the cruise control module. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Page 14177 6. Disconnect the cruise control cable bead from the fitting on the cruise control module ribbon. 7. Remove the cruise control cable from the vehicle. INSTALLATION PROCEDURE IMPORTANT: Secure all of the components of the accelerator and the cruise control cables as specified. Ensure that the throttle linkage operates freely without binding between the idle position and the wide open throttle. 1. Remove and discard the plastic cable retainer. 2. Install the cruise control cable to the vehicle. 3. Connect the cruise control cable bead to the fitting on the cruise control module ribbon. 4. Pull the cruise control cable until the cable is taut. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Page 14178 5. Use care not to twist the ribbon. 6. Turn the cruise control cable at the engine-end fitting in order to straighten the cruise control module ribbon, as needed. Ensure that the ribbon is flat and vertical. 7. Slide the cruise control cable conduit over the ribbon. ^ Install the tangs to the cruise control module housing. ^ Ensure that the tangs snap securely into place. 8. Snap the cruise control cable engine-end fitting over the stud on the throttle lever. 9. Connect the cruise control cable conduit fitting to the engine cable bracket. ^ Ensure that the tabs snap securely into the hole. ^ Route the cruise control cable above the accelerator cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Page 14179 ^ Ensure that the clip snaps securely into place. 10. Install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 14184 Cruise Control Module (CCM) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 14185 Cruise Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the bolts that retain the upper fender brace assembly. 2. Remove the upper fender brace assembly. 3. Disconnect the electrical connector at the cruise control module. 4. Remove the nuts retaining the cruise control module to the cowl. 5. Disconnect the cruise control cable from the module. 6. Remove the cruise control module from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 14186 1. Install the cruise control module to the vehicle. 2. Connect the cruise control cable to the cruise control module. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts in order to retain the cruise control module to the cowl. Tighten Tighten the nuts to 9 N.m (8O lb in). 4. Connect the electrical connector at the cruise control module. 5. Install the brace. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 14187 Tighten Tighten the bolts to 9 N.m (80 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Testing and Inspection Brake Warning Indicator: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Hydraulic System Testing and Inspection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams Cigarette Lighter: Diagrams Cigar Lighter Cigar Lighter - Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams Analog Clock Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Page 14198 Clock: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Testing and Inspection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the fuse block. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Disconnect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 7. Access the IP module yellow 2-way connector (1) located behind the IP module (2) by removing the upper IP trim panel. Refer to Trim Pad Replacement - IP Upper in Instrument Panel, Gauges and Warning Indicators. 8. Remove the CPA from the IP module yellow 2-way connector (1) located behind the IP module (2). 9. Disconnect the IP module yellow 2-way connector (1) located behind the IP module (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 14204 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the IP module yellow 2-way connector (1) located behind the main IP support. 3. Install the CPA to the IP module yellow 2-way connector (1) located behind the main IP support. 4. Connect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 5. Install the CPA (1) to the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Install the AIR BAG Fuse to the fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - SIR if the AIR BAG indicator does not operate as described. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14209 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14210 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14211 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14212 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14213 Dimmer Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14214 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14215 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14216 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14217 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14218 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14219 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14220 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14221 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14222 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14223 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14224 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14225 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14226 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14227 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14228 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14229 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14230 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14231 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14232 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14233 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14234 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14235 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14236 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14237 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14238 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14239 Dimmer Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo Door Ajar Switch - Right Cargo Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 14244 Mini Wedge (Door Jamb Switch) - LF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 14245 Mini Wedge (Door Jamb Switch) - LF - C1 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 14246 Mini Wedge (Door Jamb Switch) - LF - C3 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 14247 Door Switch: Diagrams Door Ajar Switch - Right Cargo Mini Wedge (Door Jamb Switch) - LF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 14248 Mini Wedge (Door Jamb Switch) - LF - C1 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - LF - C3 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 14249 Mini Wedge (Door Jamb Switch) - RF - C1 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - RF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 14250 Mini Wedge (Door Jamb Switch) - RF - C3 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - C1 - LR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 14251 Mini Wedge (Door Jamb Switch) - C1 - RR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams Driver Information Center (DIC) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Page 14255 Driver/Vehicle Information Display: Service and Repair REMOVAL PROCEDURE 1. Remove the rear quarter garnish molding. 2. Disconnect the electrical connector. 3. Remove the retaining screws (1). INSTALLATION PROCEDURE 1. Install the information center telltale assembly to the garnish molding. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screws (1). Tighten Tighten the retaining screws to 2 N.m (18 lb in). 3. Install the rear quarter garnish molding. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14260 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14261 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14262 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14263 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14264 Fuel Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14265 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14266 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14267 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14268 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14269 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14270 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14271 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14272 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14273 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14274 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14275 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14276 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14277 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14278 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14279 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14280 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14281 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14282 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14283 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14284 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14285 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14286 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14287 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14288 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14289 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14290 Fuel Gauge: Electrical Diagrams For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Diagrams. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Page 14291 Fuel Gauge: Description and Operation FUEL GAGE The IPC displays the fuel level as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the fuel level percent. The fuel gage defaults to empty if: ^ The PCM detects a malfunction in the fuel level sensor circuit. ^ The IPC detects a loss of class 2 communications with the PCM. When the fuel level is less than a pre-determined value, the low fuel indicator illuminates. Reviewing the fuel system description and Operation will further explain how the system functions. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Page 14292 Fuel Gauge: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Testing and Inspection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: Customer Interest Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge > Page 14301 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge > Page 14302 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge > Page 14308 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge > Page 14309 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 14310 Fuel Gauge Sender: Specifications Fuel Level Specifications Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 14311 Fuel Level Specifications Part 2 The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 14312 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 14313 Fuel Gauge Sender: Diagrams Fuel Pump/Sender - Secondary Fuel Pump/Sender - Primary Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 14314 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The Powertrain Control Module (PCM) sends the fuel level information via the class 2 circuit to the Instrument Panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 14315 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the retaining clip (6) from the fuel level sensor connector. 4. Disconnect the electrical connector (7) from under the fuel sender cover. 5. Remove the sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip (4). 3. Connect the electrical connector (7) to the fuel level sensor. 4. Connect the retaining clip (6) to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the fuse block. 5. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Disconnect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 7. Access the IP module yellow 2-way connector (1) located behind the IP module (2) by removing the upper IP trim panel. Refer to Trim Pad Replacement - IP Upper in Instrument Panel, Gauges and Warning Indicators. 8. Remove the CPA from the IP module yellow 2-way connector (1) located behind the IP module (2). 9. Disconnect the IP module yellow 2-way connector (1) located behind the IP module (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 14321 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the IP module yellow 2-way connector (1) located behind the main IP support. 3. Install the CPA to the IP module yellow 2-way connector (1) located behind the main IP support. 4. Connect the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 5. Install the CPA (1) to the steering wheel module yellow 2-way connector (2) located at the base of the steering column. 6. Install the AIR BAG Fuse to the fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - SIR if the AIR BAG indicator does not operate as described. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC Instrument Panel Control Module: Customer Interest Brakes - 'Reduced Brake Power' Shown on DIC File In Section: 05 - Brakes Bulletin No.: 02-05-23-004 Date: October, 2002 TECHNICAL Subject: Driver's Information Center (DIC) "Reduced Brake Power" Message, Reduced Vacuum Boost (Inspect/Replace Intake Manifold and Recalibrate the Instrument Panel Cluster (IPC)) Models: 2002-2003 Cadillac Escalade 2WD 2002-2003 Chevrolet Avalanche 1500 Series, Silverado, Suburban, Tahoe 2002-2003 GMC Sierra, Yukon, Yukon XL with Power Vacuum Boost Brake System (RPOs JC3 and JC4) Condition Some customers may comment on a "Reduced Brake Power" message on the DIC. Cause It is possible that a very small number of 2002 and 2003 model year vehicles may have a restriction in the vacuum booster port on the intake manifold. On the 2003 model year, only the IPC calibration is the cause of the DIC message. Correction Important: Only inspect suspect vehicles built between June 13, 2002 and August 9, 2002. Follow the service procedure to diagnose and correct this condition. 1. Open the hood and install fender covers. 2. Loosen the engine sight shield bolt. The bolt should stay in the shield. 3. Remove the engine sight shield from the sight shield retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 14330 4. Inspect the left front corner of the intake manifold for a "C" with a circle around it (2). ^ If the intake manifold DOES have a "C" (2) on it, continue with Step 5. ^ If the intake manifold DOES NOT have a "C" (2) on it, continue with Step 19. 5. Disconnect the accelerator control cable clip from the engine sight shield retainer. 6. Disconnect the cruise control cable clip from the retainer if equipped. 7. Remove the engine sight shield retainer bolts and the retainer if equipped. 8. Inspect rear center of the intake manifold just below the recycle symbol for "MADE IN CANADA" (2). ^ If the intake manifold DOES have "MADE IN CANADA" (1) on it, continue with Step 9 ^ If the intake manifold DOES NOT have "MADE IN CANADA" (1) on it, continue with Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 14331 9. Locate the vacuum booster port connector (1) on the left rear of the intake manifold. 10. Gently pull out on the vacuum booster hose (2). 11. With two fingers, push in the vacuum booster port connector lock ring (3) while gently pulling out on the vacuum booster hose (2). Important: ^ DO NOT force the drill bit into the vacuum booster intake port. ^ If the vacuum booster intake port is restricted, DO NOT attempt to remove the restriction with the drill bit. ^ If the restriction is removed with the drill bit, the material from the restriction may cause internal engine damage. ^ If the vacuum booster port is restricted, the intake manifold must be replaced. 12. Inspect the vacuum booster intake port with a 8.7 mm (11/32 in) drill bit, maximum length of 127 mm (5 in). 13. Insert the drill bit approximately 63.5 mm (2.5 in) into the vacuum booster intake port. ^ If the vacuum booster intake port IS restricted, continue with Step 14. ^ If the vacuum booster intake port IS NOT restricted, continue with Step 15. 14. Replace the intake manifold. Refer to Intake Manifold Replacement (SI Document ID # 753666). 15. Reinstall the vacuum booster hose to the vacuum booster intake port by pushing to hose nipple into the connector. 16. Install the engine sight shield retainer and the bolts. Tighten Tighten the engine sight shield retainer bolts to 5 N.m (44 lb in). 17. Install the cruise control cable clip to the retainer. 18. Install the accelerator control cable clip to the retainer if equipped. 19. Install the engine sight shield to the retainer if equipped. Tighten Tighten the engine sight shield bolt to 10 N.m (89 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 14332 20. Start the engine and fully apply the brakes four or five times in order to ensure a "good" brake pedal. Recalibrating the IPC (2003 Model Year Vehicles) 1. Vehicles Built Prior To the following VIN Breakpoints ^ 3G104569 ^ 3E117608 ^ 31118369 ^ 3Z120443 ^ 3R107568 ^ 3J101720 2. Plug in Tech 2. 3. Set the parking brake and turn the ignition ON with the engine off. 4. Reprogram the IPC following normal SPS procedures (TIS Version 9 released August 2002 or newer). 5. After reprogramming the IPC, start the vehicle and fully apply the brakes four to five times in order to ensure a "good" brake pedal and that there are no messages on the DIC. Important: The Owner's Manual Must Be Replaced After The IPC Is Recalibrated. ^ A new Owner's Manual can be ordered from Helm @ 1-800-551-4123. The dealer will be billed for the new Manual and reimbursed through the warranty claims system. ^ The Owner's Manual will be shipped to the dealer. Dealers will be required to mail the Manual to the customer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 14333 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC Instrument Panel Control Module: All Technical Service Bulletins Brakes - 'Reduced Brake Power' Shown on DIC File In Section: 05 - Brakes Bulletin No.: 02-05-23-004 Date: October, 2002 TECHNICAL Subject: Driver's Information Center (DIC) "Reduced Brake Power" Message, Reduced Vacuum Boost (Inspect/Replace Intake Manifold and Recalibrate the Instrument Panel Cluster (IPC)) Models: 2002-2003 Cadillac Escalade 2WD 2002-2003 Chevrolet Avalanche 1500 Series, Silverado, Suburban, Tahoe 2002-2003 GMC Sierra, Yukon, Yukon XL with Power Vacuum Boost Brake System (RPOs JC3 and JC4) Condition Some customers may comment on a "Reduced Brake Power" message on the DIC. Cause It is possible that a very small number of 2002 and 2003 model year vehicles may have a restriction in the vacuum booster port on the intake manifold. On the 2003 model year, only the IPC calibration is the cause of the DIC message. Correction Important: Only inspect suspect vehicles built between June 13, 2002 and August 9, 2002. Follow the service procedure to diagnose and correct this condition. 1. Open the hood and install fender covers. 2. Loosen the engine sight shield bolt. The bolt should stay in the shield. 3. Remove the engine sight shield from the sight shield retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 14339 4. Inspect the left front corner of the intake manifold for a "C" with a circle around it (2). ^ If the intake manifold DOES have a "C" (2) on it, continue with Step 5. ^ If the intake manifold DOES NOT have a "C" (2) on it, continue with Step 19. 5. Disconnect the accelerator control cable clip from the engine sight shield retainer. 6. Disconnect the cruise control cable clip from the retainer if equipped. 7. Remove the engine sight shield retainer bolts and the retainer if equipped. 8. Inspect rear center of the intake manifold just below the recycle symbol for "MADE IN CANADA" (2). ^ If the intake manifold DOES have "MADE IN CANADA" (1) on it, continue with Step 9 ^ If the intake manifold DOES NOT have "MADE IN CANADA" (1) on it, continue with Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 14340 9. Locate the vacuum booster port connector (1) on the left rear of the intake manifold. 10. Gently pull out on the vacuum booster hose (2). 11. With two fingers, push in the vacuum booster port connector lock ring (3) while gently pulling out on the vacuum booster hose (2). Important: ^ DO NOT force the drill bit into the vacuum booster intake port. ^ If the vacuum booster intake port is restricted, DO NOT attempt to remove the restriction with the drill bit. ^ If the restriction is removed with the drill bit, the material from the restriction may cause internal engine damage. ^ If the vacuum booster port is restricted, the intake manifold must be replaced. 12. Inspect the vacuum booster intake port with a 8.7 mm (11/32 in) drill bit, maximum length of 127 mm (5 in). 13. Insert the drill bit approximately 63.5 mm (2.5 in) into the vacuum booster intake port. ^ If the vacuum booster intake port IS restricted, continue with Step 14. ^ If the vacuum booster intake port IS NOT restricted, continue with Step 15. 14. Replace the intake manifold. Refer to Intake Manifold Replacement (SI Document ID # 753666). 15. Reinstall the vacuum booster hose to the vacuum booster intake port by pushing to hose nipple into the connector. 16. Install the engine sight shield retainer and the bolts. Tighten Tighten the engine sight shield retainer bolts to 5 N.m (44 lb in). 17. Install the cruise control cable clip to the retainer. 18. Install the accelerator control cable clip to the retainer if equipped. 19. Install the engine sight shield to the retainer if equipped. Tighten Tighten the engine sight shield bolt to 10 N.m (89 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 14341 20. Start the engine and fully apply the brakes four or five times in order to ensure a "good" brake pedal. Recalibrating the IPC (2003 Model Year Vehicles) 1. Vehicles Built Prior To the following VIN Breakpoints ^ 3G104569 ^ 3E117608 ^ 31118369 ^ 3Z120443 ^ 3R107568 ^ 3J101720 2. Plug in Tech 2. 3. Set the parking brake and turn the ignition ON with the engine off. 4. Reprogram the IPC following normal SPS procedures (TIS Version 9 released August 2002 or newer). 5. After reprogramming the IPC, start the vehicle and fully apply the brakes four to five times in order to ensure a "good" brake pedal and that there are no messages on the DIC. Important: The Owner's Manual Must Be Replaced After The IPC Is Recalibrated. ^ A new Owner's Manual can be ordered from Helm @ 1-800-551-4123. The dealer will be billed for the new Manual and reimbursed through the warranty claims system. ^ The Owner's Manual will be shipped to the dealer. Dealers will be required to mail the Manual to the customer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 14342 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Sun Visor: All Technical Service Bulletins Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Bulletin No.: 06-08-42-002A Date: January 23, 2007 TECHNICAL Subject: Sunshade (Visor) Vanity Mirror Bulb Inoperative (Replace Vanity Mirror Bulb Only) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2005-2007 Cadillac STS 2001-2005 Chevrolet Impala, Monte Carlo 2001-2006 Chevrolet Silverado Crew Cab, Suburban, Tahoe 2001-2006 GMC Sierra Crew Cab, Yukon, Yukon XL 2004-2005 Pontiac Grand Prix 2006-2007 HUMMER H3 Supercede: This bulletin is being updated to add the 2007 model year. Please discard Corporate Bulletin Number 06-08-42-002 (Section 08 - Body & Accessories). Condition Some customers may comment that a sunshade (visor) vanity mirror bulb is inoperative. Cause This condition may be caused by an inoperative bulb. Correction Do NOT replace the entire sunshade (visor) assembly. Replace the sunshade (visor) vanity mirror bulb with P/N 9442395 if repairing one of the affected models covered for an inoperative vanity mirror bulb. Refer to Vanity Mirror Lamp Replacement in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. > Page 14348 The vanity mirror bulb can be accessed by removing the lens. Place a flat-bladed tool in the notches and gently pry out the lens. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. > Page 14354 The vanity mirror bulb can be accessed by removing the lens. Place a flat-bladed tool in the notches and gently pry out the lens. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Always On CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. MIL OPERATION The MIL is located on the instrument panel (IP). MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. ^ The MIL illuminates during a bulb test and a system test. ^ A DTC will be stored if a MIL is requested by the diagnostic. MIL ILLUMINATION ^ The MIL will illuminate with ignition switch ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Intermittent Conditions TEST DESCRIPTION Steps 1-6 The number below refers to the step numbers on the diagnostic table. 2. The step determines if the condition is with the MIL control circuit or the PCM. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 14359 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Inoperative CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. There should be a steady MIL with the ignition ON and the engine OFF. MIL OPERATION The MIL is located on the instrument panel (IP). MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. ^ The MIL illuminates during a bulb test and a system test. ^ A DTC will be stored if a MIL is requested by the diagnostic. MIL ILLUMINATION ^ The MIL will illuminate with ignition switch ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Intermittent Conditions TEST DESCRIPTION Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 14360 Steps 1-14 The numbers below refer to the step numbers on the diagnostic table. 3. This step determines if the condition is with the MIL control circuit or the PCM. 4. This step determines if a voltage is being applied to the control circuit. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp - Transfer Case > Component Information > Service and Repair Malfunction Indicator Lamp - Transfer Case: Service and Repair Service AWD/4WD Indicator Lamp Illumination of the Lamp indicates a problem with the drive system. There will probably be a Transfer Case Code set to aid in diagnostics. The only way to get the light to go off is to clear Transfer Case codes. This light can NOT be shut off or reset any other way. Transfer Case codes should be read and repaired before clearing them. Refer to Transfer Case. See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions Odometer: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14368 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14369 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14370 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14371 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14372 Odometer: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14373 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14374 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14375 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14376 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14377 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14378 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14379 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14380 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14381 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14382 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14383 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14384 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14385 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14386 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14387 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14388 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14389 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14390 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14391 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14392 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14393 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14394 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14395 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14396 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14397 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14398 Odometer: Electrical Diagrams For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Diagrams. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Page 14399 Odometer: Description and Operation The IPC contains a season odometer and a trip odometer. Momentarily press the trip/reset switch on the IPC in order to toggle between the season odometer and the trip odometer. Press the trip/reset switch for greater than 2 seconds, while the trip odometer is displayed, in order to reset the trip odometer. The IPC displays the vehicle mileage and trip mileage as determined by the IPC. The IPC calculates the mileage based on the vehicle speed signal circuit from the PCM. The odometer will display error if an internal IPC memory failure is detected. The odometer can be configured to display either miles or kilometers. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Diagrams > Page 14400 Odometer: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Testing and Inspection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair How to Reset the CHANGE ENGINE OIL Message The GM "Oil Life System" calculates when to change your engine oil and filter based on vehicle use. Anytime your oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where you change oil prior to a CHANGE ENGINE OIL message being turned on, reset the system. To reset the CHANGE ENGINE OIL message do the following: 1. Turn the ignition key to the RUN with the engine off. 2. Fully press and release the accelerator pedal three times within five seconds. If the CHANGE ENGINE OIL message flashes for 5 seconds, the system is reset. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14408 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14409 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14410 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14411 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14412 Oil Pressure Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14413 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14414 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14415 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14416 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14417 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14418 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14419 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14420 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14421 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14422 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14423 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14424 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14425 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14426 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14427 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14428 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14429 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14430 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14431 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14432 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14433 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14434 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14435 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14436 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14437 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14438 Oil Pressure Gauge: Electrical Diagrams For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Diagrams. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Page 14439 Oil Pressure Gauge: Description and Operation ENGINE OIL PRESSURE GAGE The IPC uses the engine oil sensor signal to determine the engine oil pressure. The oil pressure sensor signal circuit is hard-wired to the IPC. The engine oil pressure sensor signal to the IPC is a variable resistance ranging from 0-90 Ohms. The sensor resistance is used to drive the engine oil pressure gage. A sensor resistance of 1 Ohm will display as 0 kPa (0 psi) and a resistance of 88 Ohms will display as 550 kPa (80 psi). The IPC monitors the oil pressure sensor signal circuit in order to decide when the oil pressure is too low. The Check Engine Oil Pressure indicator will be displayed in the message center if the IPC detects a low engine oil pressure. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Page 14440 Oil Pressure Gauge: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Testing and Inspection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Page 14444 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement - Tools Required J 41712 Oil Pressure Sensor Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Page 14445 1. Apply sealant GM U.S. P/N 12346004, Canada P/N 10953480, or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. - Tighten the oil pressure sensor to 20 Nm (15 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Park Brake Warning Lamp Switch Bolt .................................................................................................................................................. 3 Nm (25 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Specifications > Page 14449 Parking Brake Warning Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Specifications > Page 14450 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the body wiring harness junction block but do not disconnect the harness. 2. Remove the park brake warning lamp switch mounting bolt. 3. Remove the park brake warning lamp switch. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake lamp switch mounting bolt. Tighten the bolt to 3 Nm (25 inch lbs.). 3. Install the body wiring harness junction block. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC Instrument Panel Control Module: Customer Interest Brakes - 'Reduced Brake Power' Shown on DIC File In Section: 05 - Brakes Bulletin No.: 02-05-23-004 Date: October, 2002 TECHNICAL Subject: Driver's Information Center (DIC) "Reduced Brake Power" Message, Reduced Vacuum Boost (Inspect/Replace Intake Manifold and Recalibrate the Instrument Panel Cluster (IPC)) Models: 2002-2003 Cadillac Escalade 2WD 2002-2003 Chevrolet Avalanche 1500 Series, Silverado, Suburban, Tahoe 2002-2003 GMC Sierra, Yukon, Yukon XL with Power Vacuum Boost Brake System (RPOs JC3 and JC4) Condition Some customers may comment on a "Reduced Brake Power" message on the DIC. Cause It is possible that a very small number of 2002 and 2003 model year vehicles may have a restriction in the vacuum booster port on the intake manifold. On the 2003 model year, only the IPC calibration is the cause of the DIC message. Correction Important: Only inspect suspect vehicles built between June 13, 2002 and August 9, 2002. Follow the service procedure to diagnose and correct this condition. 1. Open the hood and install fender covers. 2. Loosen the engine sight shield bolt. The bolt should stay in the shield. 3. Remove the engine sight shield from the sight shield retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 14460 4. Inspect the left front corner of the intake manifold for a "C" with a circle around it (2). ^ If the intake manifold DOES have a "C" (2) on it, continue with Step 5. ^ If the intake manifold DOES NOT have a "C" (2) on it, continue with Step 19. 5. Disconnect the accelerator control cable clip from the engine sight shield retainer. 6. Disconnect the cruise control cable clip from the retainer if equipped. 7. Remove the engine sight shield retainer bolts and the retainer if equipped. 8. Inspect rear center of the intake manifold just below the recycle symbol for "MADE IN CANADA" (2). ^ If the intake manifold DOES have "MADE IN CANADA" (1) on it, continue with Step 9 ^ If the intake manifold DOES NOT have "MADE IN CANADA" (1) on it, continue with Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 14461 9. Locate the vacuum booster port connector (1) on the left rear of the intake manifold. 10. Gently pull out on the vacuum booster hose (2). 11. With two fingers, push in the vacuum booster port connector lock ring (3) while gently pulling out on the vacuum booster hose (2). Important: ^ DO NOT force the drill bit into the vacuum booster intake port. ^ If the vacuum booster intake port is restricted, DO NOT attempt to remove the restriction with the drill bit. ^ If the restriction is removed with the drill bit, the material from the restriction may cause internal engine damage. ^ If the vacuum booster port is restricted, the intake manifold must be replaced. 12. Inspect the vacuum booster intake port with a 8.7 mm (11/32 in) drill bit, maximum length of 127 mm (5 in). 13. Insert the drill bit approximately 63.5 mm (2.5 in) into the vacuum booster intake port. ^ If the vacuum booster intake port IS restricted, continue with Step 14. ^ If the vacuum booster intake port IS NOT restricted, continue with Step 15. 14. Replace the intake manifold. Refer to Intake Manifold Replacement (SI Document ID # 753666). 15. Reinstall the vacuum booster hose to the vacuum booster intake port by pushing to hose nipple into the connector. 16. Install the engine sight shield retainer and the bolts. Tighten Tighten the engine sight shield retainer bolts to 5 N.m (44 lb in). 17. Install the cruise control cable clip to the retainer. 18. Install the accelerator control cable clip to the retainer if equipped. 19. Install the engine sight shield to the retainer if equipped. Tighten Tighten the engine sight shield bolt to 10 N.m (89 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 14462 20. Start the engine and fully apply the brakes four or five times in order to ensure a "good" brake pedal. Recalibrating the IPC (2003 Model Year Vehicles) 1. Vehicles Built Prior To the following VIN Breakpoints ^ 3G104569 ^ 3E117608 ^ 31118369 ^ 3Z120443 ^ 3R107568 ^ 3J101720 2. Plug in Tech 2. 3. Set the parking brake and turn the ignition ON with the engine off. 4. Reprogram the IPC following normal SPS procedures (TIS Version 9 released August 2002 or newer). 5. After reprogramming the IPC, start the vehicle and fully apply the brakes four to five times in order to ensure a "good" brake pedal and that there are no messages on the DIC. Important: The Owner's Manual Must Be Replaced After The IPC Is Recalibrated. ^ A new Owner's Manual can be ordered from Helm @ 1-800-551-4123. The dealer will be billed for the new Manual and reimbursed through the warranty claims system. ^ The Owner's Manual will be shipped to the dealer. Dealers will be required to mail the Manual to the customer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 14463 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC Instrument Panel Control Module: All Technical Service Bulletins Brakes - 'Reduced Brake Power' Shown on DIC File In Section: 05 - Brakes Bulletin No.: 02-05-23-004 Date: October, 2002 TECHNICAL Subject: Driver's Information Center (DIC) "Reduced Brake Power" Message, Reduced Vacuum Boost (Inspect/Replace Intake Manifold and Recalibrate the Instrument Panel Cluster (IPC)) Models: 2002-2003 Cadillac Escalade 2WD 2002-2003 Chevrolet Avalanche 1500 Series, Silverado, Suburban, Tahoe 2002-2003 GMC Sierra, Yukon, Yukon XL with Power Vacuum Boost Brake System (RPOs JC3 and JC4) Condition Some customers may comment on a "Reduced Brake Power" message on the DIC. Cause It is possible that a very small number of 2002 and 2003 model year vehicles may have a restriction in the vacuum booster port on the intake manifold. On the 2003 model year, only the IPC calibration is the cause of the DIC message. Correction Important: Only inspect suspect vehicles built between June 13, 2002 and August 9, 2002. Follow the service procedure to diagnose and correct this condition. 1. Open the hood and install fender covers. 2. Loosen the engine sight shield bolt. The bolt should stay in the shield. 3. Remove the engine sight shield from the sight shield retainer. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 14469 4. Inspect the left front corner of the intake manifold for a "C" with a circle around it (2). ^ If the intake manifold DOES have a "C" (2) on it, continue with Step 5. ^ If the intake manifold DOES NOT have a "C" (2) on it, continue with Step 19. 5. Disconnect the accelerator control cable clip from the engine sight shield retainer. 6. Disconnect the cruise control cable clip from the retainer if equipped. 7. Remove the engine sight shield retainer bolts and the retainer if equipped. 8. Inspect rear center of the intake manifold just below the recycle symbol for "MADE IN CANADA" (2). ^ If the intake manifold DOES have "MADE IN CANADA" (1) on it, continue with Step 9 ^ If the intake manifold DOES NOT have "MADE IN CANADA" (1) on it, continue with Step 16. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 14470 9. Locate the vacuum booster port connector (1) on the left rear of the intake manifold. 10. Gently pull out on the vacuum booster hose (2). 11. With two fingers, push in the vacuum booster port connector lock ring (3) while gently pulling out on the vacuum booster hose (2). Important: ^ DO NOT force the drill bit into the vacuum booster intake port. ^ If the vacuum booster intake port is restricted, DO NOT attempt to remove the restriction with the drill bit. ^ If the restriction is removed with the drill bit, the material from the restriction may cause internal engine damage. ^ If the vacuum booster port is restricted, the intake manifold must be replaced. 12. Inspect the vacuum booster intake port with a 8.7 mm (11/32 in) drill bit, maximum length of 127 mm (5 in). 13. Insert the drill bit approximately 63.5 mm (2.5 in) into the vacuum booster intake port. ^ If the vacuum booster intake port IS restricted, continue with Step 14. ^ If the vacuum booster intake port IS NOT restricted, continue with Step 15. 14. Replace the intake manifold. Refer to Intake Manifold Replacement (SI Document ID # 753666). 15. Reinstall the vacuum booster hose to the vacuum booster intake port by pushing to hose nipple into the connector. 16. Install the engine sight shield retainer and the bolts. Tighten Tighten the engine sight shield retainer bolts to 5 N.m (44 lb in). 17. Install the cruise control cable clip to the retainer. 18. Install the accelerator control cable clip to the retainer if equipped. 19. Install the engine sight shield to the retainer if equipped. Tighten Tighten the engine sight shield bolt to 10 N.m (89 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 14471 20. Start the engine and fully apply the brakes four or five times in order to ensure a "good" brake pedal. Recalibrating the IPC (2003 Model Year Vehicles) 1. Vehicles Built Prior To the following VIN Breakpoints ^ 3G104569 ^ 3E117608 ^ 31118369 ^ 3Z120443 ^ 3R107568 ^ 3J101720 2. Plug in Tech 2. 3. Set the parking brake and turn the ignition ON with the engine off. 4. Reprogram the IPC following normal SPS procedures (TIS Version 9 released August 2002 or newer). 5. After reprogramming the IPC, start the vehicle and fully apply the brakes four to five times in order to ensure a "good" brake pedal and that there are no messages on the DIC. Important: The Owner's Manual Must Be Replaced After The IPC Is Recalibrated. ^ A new Owner's Manual can be ordered from Helm @ 1-800-551-4123. The dealer will be billed for the new Manual and reimbursed through the warranty claims system. ^ The Owner's Manual will be shipped to the dealer. Dealers will be required to mail the Manual to the customer. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use table. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-05-23-004 > Oct > 02 > Brakes - 'Reduced Brake Power' Shown on DIC > Page 14472 Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14478 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14479 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14480 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14481 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14482 Dimmer Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14483 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14484 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14485 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14486 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14487 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14488 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14489 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14490 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14491 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14492 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14493 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14494 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14495 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14496 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14497 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14498 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14499 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14500 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14501 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14502 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14503 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14504 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14505 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14506 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14507 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14508 Dimmer Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo Door Ajar Switch - Right Cargo Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 14513 Mini Wedge (Door Jamb Switch) - LF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 14514 Mini Wedge (Door Jamb Switch) - LF - C1 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 14515 Mini Wedge (Door Jamb Switch) - LF - C3 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 14516 Door Switch: Diagrams Door Ajar Switch - Right Cargo Mini Wedge (Door Jamb Switch) - LF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 14517 Mini Wedge (Door Jamb Switch) - LF - C1 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - LF - C3 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 14518 Mini Wedge (Door Jamb Switch) - RF - C1 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - RF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 14519 Mini Wedge (Door Jamb Switch) - RF - C3 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - C1 - LR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 14520 Mini Wedge (Door Jamb Switch) - C1 - RR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: Customer Interest Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge > Page 14529 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge > Page 14530 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge > Page 14536 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 04-08-49-018E > Jan > 05 > Fuel System - Cranks But No Start/Inaccurate Fuel Gauge > Page 14537 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 14538 Fuel Gauge Sender: Specifications Fuel Level Specifications Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 14539 Fuel Level Specifications Part 2 The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 14540 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 14541 Fuel Gauge Sender: Diagrams Fuel Pump/Sender - Secondary Fuel Pump/Sender - Primary Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 14542 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The Powertrain Control Module (PCM) sends the fuel level information via the class 2 circuit to the Instrument Panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 14543 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the retaining clip (6) from the fuel level sensor connector. 4. Disconnect the electrical connector (7) from under the fuel sender cover. 5. Remove the sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip (4). 3. Connect the electrical connector (7) to the fuel level sensor. 4. Connect the retaining clip (6) to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Park Brake Warning Lamp Switch Bolt .................................................................................................................................................. 3 Nm (25 inch lbs.) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Specifications > Page 14547 Parking Brake Warning Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Specifications > Page 14548 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the body wiring harness junction block but do not disconnect the harness. 2. Remove the park brake warning lamp switch mounting bolt. 3. Remove the park brake warning lamp switch. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake lamp switch mounting bolt. Tighten the bolt to 3 Nm (25 inch lbs.). 3. Install the body wiring harness junction block. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation The IPC displays the vehicle speed based on the vehicle speed signal from the PCM. The PCM converts the data from the vehicle speed sensor to a 4000 pulses/mile signal. The IPC uses the vehicle speed signal circuit from the PCM in order to calculate the vehicle speed. The speedometer defaults to 0 km/h (0 mph) if a malfunction in the vehicle speed signal circuit exists. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions Speedometer Head: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14556 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14557 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14558 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14559 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14560 Speedometer Head: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14561 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14562 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14563 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14564 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14565 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14566 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14567 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14568 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14569 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14570 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14571 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14572 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14573 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14574 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14575 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14576 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14577 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14578 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14579 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14580 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14581 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14582 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14583 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14584 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14585 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 14586 Speedometer Head: Electrical Diagrams For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Diagrams. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Page 14587 Speedometer Head: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Testing and Inspection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions Tachometer: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14592 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14593 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14594 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14595 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14596 Tachometer: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14597 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14598 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14599 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14600 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14601 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14602 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14603 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14604 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14605 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14606 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14607 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14608 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14609 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14610 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14611 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14612 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14613 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14614 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14615 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14616 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14617 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14618 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14619 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14620 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14621 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 14622 Tachometer: Electrical Diagrams For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Diagrams. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Page 14623 Tachometer: Description and Operation The IPC displays the engine speed based on the engine speed signal from the PCM. The IPC uses the engine speed signal circuit (2 pulses/engine revolution) from the PCM in order to calculate the engine speed. The tachometer defaults to 0 rpm if a malfunction in the engine speed signal circuit exists. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Page 14624 Tachometer: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Testing and Inspection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions Temperature Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14629 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14630 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14631 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14632 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14633 Temperature Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14634 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14635 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14636 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14637 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14638 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14639 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14640 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14641 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14642 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14643 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14644 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14645 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14646 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14647 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14648 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14649 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14650 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14651 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14652 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14653 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14654 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14655 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14656 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14657 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14658 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 14659 Temperature Gauge: Electrical Diagrams For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Diagrams. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Page 14660 Temperature Gauge: Description and Operation ENGINE COOLANT TEMPERATURE GAGE The IPC displays the engine coolant temperature as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the engine coolant temperature. The engine coolant temperature gage defaults to 75°C (160°F) or below when: ^ The PCM detects a malfunction in the engine coolant temperature sensor circuit. ^ The IPC detects a loss of class 2 communication with the PCM. TRANSMISSION TEMPERATURE GAGE The IPC displays the transmission temperature as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the transmission temperature. The transmission temperature gage will default to 40°C (100°F) or below if: ^ The PCM detects a malfunction in the transmission temperature sensor circuit. ^ The IPC detects a loss of class 2 communications with the PCM. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Page 14661 Temperature Gauge: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators, Testing and Inspection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Technical Service Bulletins > Instruments - Reduced PRNDL Display Visibility Transmission Shift Position Indicator Lamp: Technical Service Bulletins Instruments - Reduced PRNDL Display Visibility Bulletin No.: 02-08-42-004A Date: March 30, 2007 INFORMATION Subject: PRNDL Display Reduced Visibility For Approximately One Minute Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Headlamp Control and Vacuum Fluorescent PRNDL Indicator Instrument Panel Cluster Supercede: This bulletin is being revised to include additional models and model years. Please discard Corporate Bulletin Number 02-08-42-0004 (Section 08 - Body and Accessories). After backing the vehicle out of a garage or dark environment into a daylight environment, the PRNDL display has reduced visibility for approximately one minute. While the vehicle is parked in a dark environment, the sensor for the automatic headlamp/driving lamps senses that it is dark. When the key is turned to the run/start position, the automatic headlamp module will turn all driving lamps, the instrument panel cluster and PRNDL display ON in the night-time mode. The night-time mode intensity of the instrument panel lamps and PRNDL display is controlled by the automatic headlamp module and can be dimmed further by the customer using the dimming control of the headlamp switch. When the customer then moves the vehicle from the dark environment into the bright sunlight, it will take approximately one minute before the headlamp control module recognizes this as true daylight and not just a bright overhead street lamp shining on the sensor. The headlamp control module will then turn the headlamps off and restore the instrument panel and PRNDL display to full brilliance. Without the time delay, the automatic headlamp control module would switch to the night mode (turn on all driving lamps, instrument panel lamps and PRNDL display would dim) each time the vehicle was driven under an overpass or other darkened environment. This is a normal condition and no repair should be attempted. Ensure the instrument panel backlighting control is in the full bright position. This will help alleviate the condition. You may demonstrate to the customer what happens by placing a repair order over the automatic headlamp control light sensor, which will cause the automatic headlamp control module to switch to the night mode in approximately one minute. All driving lamps will come ON, the instrument panel backlight will be dim, and the PRNDL display will also dim to the night setting in conjunction with the position of the headlamp switch dimming control. Demonstrate to the customer the variance in the instrument panel backlighting and PRNDL display while adjusting the headlamp switch dimming control to both ends of its allowable range. Advise the customer to keep the headlight switch dimming control in the highest position to allow viewing of the PRNDL display in a bright environment. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions Ambient Light Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14680 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14681 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14682 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14683 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14684 Ambient Light Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14685 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14686 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14687 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14688 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14689 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14690 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14691 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14692 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14693 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14694 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14695 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14696 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14697 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14698 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14699 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14700 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14701 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14702 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14703 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14704 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14705 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14706 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14707 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14708 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14709 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 14710 Ambient Light Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 14711 Ambient Light Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the instrument panel top cover. 2. Disconnect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Turn the ambient light sensor 1/4 turn and remove it from the IP top cover. INSTALLATION PROCEDURE 1. Install the ambient light sensor to the underside of the IP top cover, turning it 1/4 turn to secure it in place. 2. Connect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Install the instrument panel top cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14717 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14718 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14719 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14720 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14721 Backup Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14722 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14723 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14724 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14725 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14726 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14727 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14728 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14729 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14730 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14731 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14732 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14733 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14734 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14735 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14736 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14737 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14738 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14739 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14740 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14741 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14742 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14743 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14744 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14745 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14746 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14752 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14753 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14754 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14755 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14756 Brake Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14757 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14758 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14759 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14760 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14761 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14762 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14763 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14764 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14765 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14766 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14767 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14768 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14769 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14770 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14771 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14772 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14773 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14774 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14775 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14776 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14777 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14778 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14779 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14780 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14781 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Light Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14787 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14788 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14789 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14790 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14791 Brake Light Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14792 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14793 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14794 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14795 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14796 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14797 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14798 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14799 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14800 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14801 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14802 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14803 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14804 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14805 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14806 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14807 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14808 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14809 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14810 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14811 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14812 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14813 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14814 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14815 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14816 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14817 Stop Lamp Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 14818 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement Removal Procedure 1. Disconnect the electrical connector from the stop lamp switch (2). 2. Remove the pushrod retaining clip (4). 3. Remove the stop lamp switch (2). Installation Procedure 1. Install the stop lamp switch (2). 2. Install the pushrod retaining clip (4). 3. Connect the electrical connector to the stop lamp switch (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Cargo Lamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14825 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14826 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14827 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14828 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14829 Cargo Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14830 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14831 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14832 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14833 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14834 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14835 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14836 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14837 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14838 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14839 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14840 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14841 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14842 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14843 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14844 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14845 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14846 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14847 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14848 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14849 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14850 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14851 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14852 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14853 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14854 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 14855 Cargo Lamp Switch: Connector Views Fog/Cargo Lamp Switch Part 2 Fog/Cargo Lamp Switch Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Diagrams > Page 14856 Cargo Lamp Switch: Service and Repair LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Center Mounted Brake Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14862 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14863 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14864 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14865 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14866 Center Mounted Brake Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14867 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14868 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14869 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14870 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14871 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14872 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14873 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14874 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14875 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14876 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14877 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14878 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14879 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14880 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14881 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14882 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14883 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14884 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14885 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14886 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14887 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14888 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14889 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14890 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14891 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14892 Center High Mounted Stop Lamp (CHMSL) - Except Avalanche/Escalade EXT Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 14893 Center Mounted Brake Lamp: Service and Repair REMOVAL PROCEDURE 1. Ensure the headlamp switch is in the OFF position. 2. Remove the upper garnish molding at the headliner. 3. Pull back the right and left side rear window garnish molding. 4. Lower the rear of the headliner in order to access the electrical connector. 5. Disconnect the electrical connector (4). 6. Attach a short piece of wire to the high mounted stoplamp connector in order to assist the guiding of the harness through the body. 7. Remove the high mounted stoplamp screws (2). 8. Remove the high mounted stoplamp (1) from the vehicle. INSTALLATION PROCEDURE 1. Attach the harness to the guide wire. 2. Using the guide wire, pull the lamp wire through the hole in the roof panel. 3. Remove the guide wire. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the high mounted stoplamp (1) to the vehicle with the screws (2). Tighten Tighten the screws to 2 N.m (17 lb in). 5. Connect the electrical connector (4). 6. Install the headliner. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 14894 7. Install the left and right side rear window garnish molding. 8. Install the rear upper garnish molding. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Locations > Component Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Locations > Component Locations > Page 14899 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions Clearance Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14902 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14903 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14904 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14905 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14906 Clearance Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14907 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14908 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14909 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14910 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14911 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14912 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14913 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14914 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14915 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14916 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14917 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14918 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14919 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14920 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14921 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14922 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14923 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14924 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14925 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14926 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14927 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14928 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14929 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14930 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14931 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14932 Clearance Lamps Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Page 14933 Clearance Lamp: Description and Operation The clearance lamps are turned on when the headlamp switch is placed in the PARK or ON position or anytime the headlights are requested. The PARK LPS 30 A fuse in the engine wiring harness junction block supplies battery positive voltage to both the park lamp relay switch contacts and the park lamp coil circuit. The body control module (BCM) provides a ground or control circuit to the park lamp relay coil circuit. When the park lamps are turned on the BCM energizes the park lamp relay. Current flow is from the park lamp relay to the INT PRK 10 A fuse, and to clearance lamps. The clearance lamps are grounded at G200. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions Ash Tray Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14940 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14941 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14942 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14943 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14944 Ash Tray Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14945 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14946 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14947 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14948 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14949 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14950 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14951 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14952 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14953 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14954 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14955 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14956 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14957 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14958 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14959 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14960 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14961 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14962 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14963 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14964 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14965 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14966 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14967 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14968 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14969 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14970 Ashtray Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Page 14971 Ash Tray Lamp: Service and Repair REMOVAL PROCEDURE 1. Ensure the headlamp switch is in the OFF position. 2. Remove the knee bolster. 3. Squeeze the sides of the instrument panel storage compartment. 4. Pull out the compartment. 5. Remove the ashtray assembly by unsnapping the retainers. 6. Remove the lamp assembly and the shield from the top of the ashtray bracket. 7. Remove the shield from the lamp assembly. 8. Remove the bulb from the base by pulling the bulb straight out of the base. INSTALLATION PROCEDURE 1. Install the bulb into the base by pushing the bulb straight into the base. 2. Install the shield to the lamp assembly. 3. Install the lamp assembly and the shield to the top of the ashtray bracket. 4. Install the ashtray assembly to the instrument panel. 5. Install the instrument panel storage compartment. 6. Install the knee bolster. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions Console Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14976 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14977 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14978 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14979 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14980 Console Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14981 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14982 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14983 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14984 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14985 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14986 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14987 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14988 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14989 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14990 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14991 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14992 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14993 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14994 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14995 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14996 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14997 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14998 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 14999 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15000 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15001 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15002 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15003 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15004 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15005 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Page 15006 Console Lamp: Service and Repair REMOVAL PROCEDURE IMPORTANT: Do not disconnect the electrical connectors. 1. Remove and move the console end panel rearwards. 2. Press on the tabs (1) in order to remove the lamp assembly from the end panel. 3. Disconnect the electrical connector. 4. To replace the bulb, turn counter clockwise to remove. INSTALLATION PROCEDURE 1. Install the bulb by turning clockwise. 2. Connect the electrical connector to the lamp. 3. Push in the lamp assembly until the tabs (1) are fully seated. 4. Install the console end panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions Door Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15011 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15012 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15013 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15014 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15015 Door Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15016 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15017 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15018 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15019 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15020 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15021 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15022 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15023 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15024 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15025 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15026 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15027 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15028 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15029 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15030 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15031 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15032 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15033 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15034 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15035 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15036 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15037 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15038 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15039 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15040 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15041 Door Courtesy Lamp - LF, RF, LR, RR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions Glove Box Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15046 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15047 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15048 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15049 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15050 Glove Box Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15051 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15052 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15053 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15054 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15055 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15056 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15057 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15058 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15059 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15060 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15061 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15062 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15063 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15064 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15065 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15066 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15067 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15068 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15069 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15070 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15071 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15072 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15073 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15074 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15075 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15076 IP Compartment Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Page 15077 Glove Box Lamp: Description and Operation IP COMPARTMENT LAMP The inadvertent power relay provides battery positive voltage to the instrument panel compartment lamp. When the IP compartment is opened, its switch closes to provide a ground circuit and the IP compartment lamp illuminates. The IP compartment lamp is grounded at G102. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Page 15078 Glove Box Lamp: Service and Repair IP COMPARTMENT LAMP REPLACEMENT REMOVAL PROCEDURE 1. Ensure the headlamp switch is in the OFF position. 2. Lower the instrument panel storage compartment door by pressing in the tab. 3. Depress the switch plunger. 4. Pull the switch assembly downward from the retainer. 5. Disconnect the electrical connector. 6. Remove the shield from the switch assembly. 7. Remove the bulb from the switch assembly. INSTALLATION PROCEDURE 1. Install the bulb into the socket. 2. Install the shield to the switch assembly. 3. Connect the electrical connector. 4. Depress the switch plunger. 5. Slide the assembly upward into the retainer. 6. Close the instrument panel storage compartment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions Daytime Running Lamp Control Unit: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15084 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15085 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15086 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15087 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15088 Daytime Running Lamp Control Unit: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15089 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15090 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15091 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15092 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15093 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15094 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15095 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15096 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15097 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15098 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15099 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15100 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15101 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15102 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15103 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15104 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15105 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15106 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15107 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15108 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15109 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15110 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15111 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15112 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15113 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions Daytime Running Lamp Diode Assembly: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15118 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15119 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15120 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15121 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15122 Daytime Running Lamp Diode Assembly: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15123 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15124 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15125 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15126 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15127 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15128 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15129 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15130 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15131 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15132 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15133 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15134 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15135 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15136 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15137 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15138 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15139 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15140 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15141 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15142 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15143 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15144 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15145 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15146 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams > Diagram Information and Instructions > Page 15147 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Page 15151 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Daytime Running Lamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15154 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15155 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15156 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15157 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15158 Daytime Running Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15159 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15160 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15161 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15162 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15163 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15164 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15165 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15166 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15167 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15168 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15169 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15170 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15171 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15172 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15173 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15174 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15175 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15176 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15177 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15178 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15179 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15180 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15181 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15182 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15183 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Page 15184 Daytime Running Lamp Relay: Service and Repair REMOVAL PROCEDURE 1. Open the electrical center cover (2). 2. Using the relays/fuses diagram, locate the DRL relay. 3. Remove the relay from the underhood electrical center. INSTALLATION PROCEDURE 1. Refer to the diagram for the relays/fuses in the cover locate the position of the relay. 2. Install the relay in the electrical center. 3. Install the cover (2). 4. Start and vehicle and shift gear lever out of park. Ask an assistant to look in front of vehicle to ensure the DRL are operating. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15189 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15190 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15191 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15192 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15193 Dimmer Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15194 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15195 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15196 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15197 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15198 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15199 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15200 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15201 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15202 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15203 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15204 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15205 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15206 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15207 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15208 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15209 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15210 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15211 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15212 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15213 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15214 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15215 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15216 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15217 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15218 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15219 Dimmer Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions Dome Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15224 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15225 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15226 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15227 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15228 Dome Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15229 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15230 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15231 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15232 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15233 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15234 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15235 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15236 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15237 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15238 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15239 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15240 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15241 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15242 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15243 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15244 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15245 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15246 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15247 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15248 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15249 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15250 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15251 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15252 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15253 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15254 Dome Lamp - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 15255 Dome Lamp: Service and Repair REMOVAL PROCEDURE 1. Remove the lamp lens assembly using a small screw driver. 2. Remove the dome lamp assembly from the headliner. 3. Disconnect the electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 15256 4. Remove the bulb. INSTALLATION PROCEDURE 1. Install the bulb. 2. Connect the electrical connector. 3. Install the dome lamp assembly into the headliner. 4. Press the lens into place. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo Door Ajar Switch - Right Cargo Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 15261 Mini Wedge (Door Jamb Switch) - LF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 15262 Mini Wedge (Door Jamb Switch) - LF - C1 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 15263 Mini Wedge (Door Jamb Switch) - LF - C3 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 15264 Door Switch: Diagrams Door Ajar Switch - Right Cargo Mini Wedge (Door Jamb Switch) - LF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 15265 Mini Wedge (Door Jamb Switch) - LF - C1 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - LF - C3 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 15266 Mini Wedge (Door Jamb Switch) - RF - C1 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - RF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 15267 Mini Wedge (Door Jamb Switch) - RF - C3 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - C1 - LR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 15268 Mini Wedge (Door Jamb Switch) - C1 - RR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Exterior Lighting Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15273 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15274 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15275 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15276 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15277 Exterior Lighting Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15278 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15279 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15280 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15281 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15282 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15283 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15284 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15285 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15286 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15287 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15288 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15289 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15290 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15291 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15292 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15293 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15294 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15295 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15296 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15297 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15298 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15299 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15300 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15301 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15302 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15303 Roof Beacon Relay Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Fog Lamp Bulb Replacement - Front Fog/Driving Lamp Bulb: Service and Repair Fog Lamp Bulb Replacement - Front REMOVAL PROCEDURE 1. Remove the electrical connector. CAUTION: Refer to Halogen Bulb Caution in Service Precautions. 2. Remove the bulb from the fog lamp assembly by twisting the bulb counterclockwise and pulling the bulb out. INSTALLATION PROCEDURE 1. Install the bulb to the fog lamp assembly by inserting the bulb and twisting the bulb clockwise. 2. Install the electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Fog Lamp Bulb Replacement - Front > Page 15309 Fog/Driving Lamp Bulb: Service and Repair Fog Lamp Bulb Replacement - Rear REMOVAL PROCEDURE 1. Remove the rear fog lamp lens (1) retaining screws (2). CAUTION: Refer to Halogen Bulb Caution in Service Precautions. 2. Remove the bulb from the rear fog lamp assembly by twisting the bulb counterclockwise and pulling the bulb out. INSTALLATION PROCEDURE 1. Install the bulb to the rear fog lamp assembly by inserting the bulb and twisting the bulb clockwise. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear fog lamp lens (1) retaining screws (2). Tighten Tighten the screws (2) to 2 N.m (18 lb in). 3. Inspect the operation of the rear fog lamp. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 15313 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Fog/Driving Lamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15316 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15317 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15318 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15319 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15320 Fog/Driving Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15321 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15322 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15323 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15324 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15325 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15326 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15327 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15328 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15329 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15330 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15331 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15332 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15333 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15334 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15335 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15336 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15337 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15338 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15339 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15340 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15341 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15342 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15343 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15344 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15345 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations Fog/Driving Lamp Switch: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 15349 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Fog/Driving Lamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15352 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15353 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15354 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15355 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15356 Fog/Driving Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15357 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15358 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15359 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15360 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15361 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15362 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15363 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15364 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15365 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15366 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15367 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15368 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15369 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15370 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15371 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15372 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15373 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15374 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15375 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15376 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15377 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15378 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15379 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15380 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15381 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15382 Fog/Driving Lamp Switch: Connector Views Fog/Cargo Lamp Switch Part 2 Fog/Cargo Lamp Switch Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15383 Rear Wiper/Washer And Fog Lamp Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Service and Repair > Lamp Switch ASSY Replacement - Front Fog Lamp and Cargo Lamp Fog/Driving Lamp Switch: Service and Repair Lamp Switch ASSY Replacement - Front Fog Lamp and Cargo Lamp REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Service and Repair > Lamp Switch ASSY Replacement - Front Fog Lamp and Cargo Lamp > Page 15386 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement - Rear REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the fog lamp switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the fog lamp switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Flasher: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15392 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15393 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15394 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15395 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15396 Hazard Warning Flasher: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15397 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15398 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15399 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15400 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15401 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15402 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15403 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15404 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15405 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15406 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15407 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15408 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15409 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15410 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15411 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15412 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15413 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15414 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15415 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15416 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15417 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15418 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15419 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15420 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 15421 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Page 15422 Hazard Warning Flasher: Service and Repair HAZARD AND TURN SIGNAL FLASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the knee bolster. 2. On the back side of the fuse block release the retainer while pulling the flasher (1) outwards. 3. Remove the flasher (1) from the fuse block. INSTALLATION PROCEDURE 1. Install the flasher (1) to the fuse block until the retainer clicks into place. 2. Install the knee bolster. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15427 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15428 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15429 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15430 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15431 Hazard Warning Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15432 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15433 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15434 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15435 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15436 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15437 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15438 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15439 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15440 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15441 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15442 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15443 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15444 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15445 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15446 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15447 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15448 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15449 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15450 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15451 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15452 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15453 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15454 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15455 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15456 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Halogen Bulb Caution in Service Precautions. NOTE: Refer to Avoid Touching the Bulb in Service Precautions. 1. Open the hood. Rotate the headlamp retainer pins. 2. Remove the headlamp retainer pins. 3. Pull out the headlamp assembly in order to access the electrical connector. 4. Disconnect the electrical connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 15461 5. Remove the bulb from the headlamp assembly by twisting the bulb counterclockwise. INSTALLATION PROCEDURE IMPORTANT: Replace a high beam bulb with another high beam bulb. The high beam bulb has a red gasket. - Replace a low beam bulb with another low beam bulb. The low beam bulb has a gray tip and a yellow gasket at the base. 1. Install the new bulb to the headlamp assembly by twisting the bulb clockwise in order to lock in place. 2. Connect the electrical connector to the bulb. 3. Install the headlamp assembly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 15462 4. Install the headlamp retainer pins. 5. Rotate and lock the pins in place. 6. Inspect the operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15467 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15468 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15469 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15470 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15471 Headlamp Dimmer Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15472 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15473 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15474 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15475 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15476 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15477 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15478 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15479 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15480 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15481 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15482 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15483 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15484 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15485 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15486 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15487 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15488 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15489 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15490 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15491 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15492 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15493 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15494 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15495 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15496 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Technical Service Bulletins > Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 15504 Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions Headlamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15507 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15508 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15509 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15510 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15511 Headlamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15512 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15513 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15514 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15515 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15516 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15517 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15518 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15519 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15520 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15521 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15522 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15523 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15524 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15525 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15526 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15527 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15528 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15529 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15530 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15531 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15532 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15533 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15534 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15535 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15536 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15542 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15543 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15544 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15545 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15546 Headlamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15547 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15548 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15549 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15550 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15551 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15552 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15553 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15554 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15555 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15556 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15557 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15558 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15559 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15560 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15561 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15562 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15563 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15564 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15565 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15566 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15567 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15568 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15569 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15570 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 15571 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement Headlamp Switch: Service and Repair Headlamp Switch Replacement REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Unsnap the switch from the housing. 3. Disconnect the electrical connectors. 4. Remove the switch. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement > Page 15574 1. Connect the electrical connectors. 2. Install the headlamp switch by snapping the headlamps switch into place. 3. Install the bezel to the instrument panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement > Page 15575 Headlamp Switch: Service and Repair Headlamp Leveling Switch Replacement REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the head lamp leveling switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the head lamp leveling switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Hi-Beam Indicator Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15580 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15581 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15582 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15583 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15584 Hi-Beam Indicator Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15585 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15586 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15587 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15588 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15589 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15590 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15591 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15592 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15593 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15594 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15595 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15596 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15597 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15598 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15599 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15600 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15601 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15602 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15603 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15604 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15605 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15606 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15607 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15608 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15609 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 15614 Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Service and Repair Lamp Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the IP trim bezel. 2. Remove the head lamp switch/4WD shift button housing from the IP by pulling outwards. The arrows in the graphic shows the locations of the retaining clips. 3. Disconnect all the electrical connectors. 4. Remove the electrical tape around the lamp module and discard. 5. Remove the lamp module from the connector by pulling outwards. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Service and Repair > Page 15618 1. Install the lamp module to the connector until fully seated. IMPORTANT: Do not tape past the line where the cooling fins begin. Taping around the fins will result in the module overheating. 2. Install a new electrical tape around the module in order to secure the module to the IP wire harness. 3. Connect all the electrical connectors. 4. Install the head lamp switch/4WD shift button housing to the IP so that the retainers are fully seated. 5. Install the IP trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Locations License Plate Lamp: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Locations > Page 15622 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15625 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15626 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15627 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15628 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15629 License Plate Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15630 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15631 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15632 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15633 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15634 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15635 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15636 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15637 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15638 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15639 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15640 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15641 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15642 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15643 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15644 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15645 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15646 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15647 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15648 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15649 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15650 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15651 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15652 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15653 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15654 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15655 License Plate Lamp: Connector Views License Lamp - LR License Lamp - RR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 15656 License Plate Lamp: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 15657 License Plate Lamp: Service and Repair REMOVAL PROCEDURE 1. Ensure the headlamp switch is in the OFF position. 2. Remove the lens from the lamp assembly. 3. Remove the bulb. INSTALLATION PROCEDURE 1. Install the bulb. 2. Install the lens to the lamp assembly. 3. Inspect the operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions Map Light: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15662 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15663 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15664 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15665 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15666 Map Light: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15667 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15668 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15669 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15670 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15671 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15672 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15673 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15674 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15675 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15676 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15677 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15678 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15679 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15680 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15681 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15682 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15683 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15684 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15685 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15686 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15687 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15688 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15689 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15690 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15691 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15692 Map Light: Connector Views Reading Lamps Overhead Console Courtesy/Reading Lamp - Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 15693 Courtesy/Reading Lamp - Uplevel Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations Marker Lamp: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Page 15697 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15700 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15701 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15702 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15703 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15704 Marker Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15705 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15706 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15707 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15708 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15709 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15710 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15711 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15712 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15713 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15714 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15715 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15716 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15717 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15718 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15719 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15720 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15721 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15722 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15723 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15724 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15725 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15726 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15727 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15728 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15729 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15730 Marker Lamp: Connector Views Marker Lamp - LF Marker Lamp - RF Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 15731 Roof Marker Lamps - Left, Right Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 15732 Marker Lamp: Description and Operation PARK, TAIL AND MARKER LAMPS The park, tail and marker lamps, including the license lamps, are turned on when the headlamp switch is placed in the PARK or ON position or anytime the headlights are requested. The PARK LPS 30 A fuse in the engine wiring harness junction block supplies battery positive voltage to both the park lamp relay switch contacts and the park lamp coil circuit. The Body Control Module (BCM) provides a ground or control circuit to the park lamp relay coil circuit. When the park lamps are turned on the BCM energizes the park lamp relay. Current flow is from the park lamp relay to the FR PRK 10 A fuse, RR PRK 10 A fuse LR PRK 10 A fuse, and the TRL PRK 15 A fuse, and to their respective park and marker lamps. The front park and marker lamps are grounded at G100. The rear park and marker lamps are grounded at G401. The license lamps are grounded at G401. If the headlight switch is left in the ON position, the inadvertent power control feature will turn off the park, tail and marker lamps approximately 10 minutes after the ignition switch is turned to the OFF position. If the driver places the headlight switch in the ON position after the ignition switch has been turned OFF, or if the ignition switch is in the ACCY position, the park, tail and marker lamps will remain on until turned off or the battery runs dead. The CTSY LMP 15 A fuse in the engine wiring harness junction block supplies battery positive voltage to both the inadvertent power relay switch contacts and the inadvertent power relay coil circuit. The body control module (BCM) provides a ground or control circuit to the park lamp relay coil circuit. When the driver presses the cargo lamp switch, the BCM energizes the inadvertent power relay. Current flow is from the inadvertent power relay to the cargo lamps. The cargo lamps are grounded at G203. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 15733 Marker Lamp: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Parking Lamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15739 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15740 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15741 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15742 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15743 Parking Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15744 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15745 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15746 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15747 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15748 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15749 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15750 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15751 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15752 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15753 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15754 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15755 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15756 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15757 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15758 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15759 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15760 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15761 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15762 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15763 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15764 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15765 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15766 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15767 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15768 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15774 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15775 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15776 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15777 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15778 Brake Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15779 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15780 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15781 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15782 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15783 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15784 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15785 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15786 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15787 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15788 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15789 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15790 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15791 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15792 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15793 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15794 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15795 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15796 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15797 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15798 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15799 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15800 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15801 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15802 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15803 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions Daytime Running Lamp Control Unit: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15808 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15809 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15810 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15811 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15812 Daytime Running Lamp Control Unit: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15813 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15814 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15815 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15816 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15817 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15818 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15819 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15820 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15821 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15822 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15823 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15824 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15825 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15826 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15827 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15828 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15829 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15830 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15831 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15832 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15833 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15834 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15835 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15836 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 15837 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 15841 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Daytime Running Lamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15844 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15845 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15846 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15847 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15848 Daytime Running Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15849 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15850 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15851 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15852 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15853 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15854 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15855 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15856 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15857 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15858 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15859 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15860 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15861 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15862 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15863 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15864 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15865 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15866 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15867 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15868 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15869 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15870 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15871 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15872 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15873 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Page 15874 Daytime Running Lamp Relay: Service and Repair REMOVAL PROCEDURE 1. Open the electrical center cover (2). 2. Using the relays/fuses diagram, locate the DRL relay. 3. Remove the relay from the underhood electrical center. INSTALLATION PROCEDURE 1. Refer to the diagram for the relays/fuses in the cover locate the position of the relay. 2. Install the relay in the electrical center. 3. Install the cover (2). 4. Start and vehicle and shift gear lever out of park. Ask an assistant to look in front of vehicle to ensure the DRL are operating. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Exterior Lighting Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15879 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15880 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15881 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15882 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15883 Exterior Lighting Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15884 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15885 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15886 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15887 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15888 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15889 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15890 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15891 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15892 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15893 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15894 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15895 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15896 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15897 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15898 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15899 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15900 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15901 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15902 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15903 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15904 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15905 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15906 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15907 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15908 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15909 Roof Beacon Relay Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 15913 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Fog/Driving Lamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15916 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15917 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15918 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15919 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15920 Fog/Driving Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15921 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15922 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15923 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15924 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15925 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15926 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15927 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15928 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15929 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15930 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15931 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15932 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15933 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15934 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15935 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15936 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15937 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15938 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15939 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15940 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15941 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15942 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15943 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15944 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15945 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 15949 Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions Headlamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15952 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15953 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15954 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15955 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15956 Headlamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15957 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15958 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15959 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15960 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15961 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15962 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15963 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15964 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15965 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15966 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15967 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15968 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15969 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15970 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15971 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15972 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15973 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15974 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15975 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15976 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15977 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15978 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15979 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15980 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15981 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 15985 Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Service and Repair Lamp Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the IP trim bezel. 2. Remove the head lamp switch/4WD shift button housing from the IP by pulling outwards. The arrows in the graphic shows the locations of the retaining clips. 3. Disconnect all the electrical connectors. 4. Remove the electrical tape around the lamp module and discard. 5. Remove the lamp module from the connector by pulling outwards. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Service and Repair > Page 15989 1. Install the lamp module to the connector until fully seated. IMPORTANT: Do not tape past the line where the cooling fins begin. Taping around the fins will result in the module overheating. 2. Install a new electrical tape around the module in order to secure the module to the IP wire harness. 3. Connect all the electrical connectors. 4. Install the head lamp switch/4WD shift button housing to the IP so that the retainers are fully seated. 5. Install the IP trim bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Parking Lamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15994 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15995 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15996 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15997 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15998 Parking Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15999 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16000 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16001 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16002 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16003 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16004 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16005 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16006 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16007 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16008 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16009 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16010 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16011 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16012 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16013 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16014 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16015 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16016 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16017 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16018 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16019 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16020 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16021 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16022 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16023 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16032 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16033 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16039 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16040 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16045 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16046 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16047 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16048 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16049 Turn Signal Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16050 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16051 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16052 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16053 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16054 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16055 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16056 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16057 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16058 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16059 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16060 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16061 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16062 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16063 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16064 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16065 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16066 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16067 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16068 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16069 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16070 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16071 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16072 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16073 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16074 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions Ambient Light Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16080 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16081 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16082 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16083 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16084 Ambient Light Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16085 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16086 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16087 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16088 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16089 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16090 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16091 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16092 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16093 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16094 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16095 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16096 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16097 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16098 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16099 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16100 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16101 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16102 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16103 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16104 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16105 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16106 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16107 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16108 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16109 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 16110 Ambient Light Sensor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 16111 Ambient Light Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the instrument panel top cover. 2. Disconnect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Turn the ambient light sensor 1/4 turn and remove it from the IP top cover. INSTALLATION PROCEDURE 1. Install the ambient light sensor to the underside of the IP top cover, turning it 1/4 turn to secure it in place. 2. Connect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Install the instrument panel top cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16116 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16117 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16118 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16119 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16120 Backup Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16121 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16122 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16123 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16124 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16125 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16126 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16127 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16128 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16129 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16130 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16131 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16132 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16133 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16134 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16135 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16136 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16137 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16138 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16139 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16140 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16141 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16142 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16143 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16144 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16145 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Light Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16151 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16152 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16153 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16154 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16155 Brake Light Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16156 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16157 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16158 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16159 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16160 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16161 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16162 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16163 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16164 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16165 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16166 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16167 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16168 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16169 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16170 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16171 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16172 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16173 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16174 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16175 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16176 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16177 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16178 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16179 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16180 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16181 Stop Lamp Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 16182 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement Removal Procedure 1. Disconnect the electrical connector from the stop lamp switch (2). 2. Remove the pushrod retaining clip (4). 3. Remove the stop lamp switch (2). Installation Procedure 1. Install the stop lamp switch (2). 2. Install the pushrod retaining clip (4). 3. Connect the electrical connector to the stop lamp switch (2). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Cargo Lamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16188 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16189 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16190 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16191 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16192 Cargo Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16193 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16194 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16195 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16196 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16197 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16198 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16199 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16200 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16201 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16202 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16203 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16204 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16205 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16206 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16207 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16208 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16209 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16210 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16211 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16212 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16213 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16214 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16215 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16216 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16217 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16218 Cargo Lamp Switch: Connector Views Fog/Cargo Lamp Switch Part 2 Fog/Cargo Lamp Switch Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Diagrams > Page 16219 Cargo Lamp Switch: Service and Repair LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions Combination Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16224 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16225 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16226 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16227 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16228 Combination Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16229 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16230 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16231 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16232 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16233 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16234 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16235 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16236 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16237 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16238 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16239 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16240 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16241 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16242 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16243 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16244 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16245 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16246 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16247 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16248 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16249 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16250 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16251 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16252 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16253 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo Door Ajar Switch - Right Cargo Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 16258 Mini Wedge (Door Jamb Switch) - LF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 16259 Mini Wedge (Door Jamb Switch) - LF - C1 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 16260 Mini Wedge (Door Jamb Switch) - LF - C3 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 16261 Door Switch: Diagrams Door Ajar Switch - Right Cargo Mini Wedge (Door Jamb Switch) - LF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 16262 Mini Wedge (Door Jamb Switch) - LF - C1 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - LF - C3 - Uplevel/Luxury Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 16263 Mini Wedge (Door Jamb Switch) - RF - C1 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - RF - C1 - Base Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 16264 Mini Wedge (Door Jamb Switch) - RF - C3 - Uplevel/Luxury Mini Wedge (Door Jamb Switch) - C1 - LR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch - Right Cargo > Page 16265 Mini Wedge (Door Jamb Switch) - C1 - RR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations Fog/Driving Lamp Switch: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 16269 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Fog/Driving Lamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16272 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16273 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16274 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16275 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16276 Fog/Driving Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16277 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16278 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16279 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16280 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16281 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16282 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16283 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16284 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16285 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16286 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16287 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16288 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16289 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16290 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16291 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16292 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16293 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16294 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16295 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16296 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16297 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16298 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16299 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16300 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16301 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16302 Fog/Driving Lamp Switch: Connector Views Fog/Cargo Lamp Switch Part 2 Fog/Cargo Lamp Switch Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16303 Rear Wiper/Washer And Fog Lamp Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Lamp Switch ASSY Replacement - Front Fog Lamp and Cargo Lamp Fog/Driving Lamp Switch: Service and Repair Lamp Switch ASSY Replacement - Front Fog Lamp and Cargo Lamp REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Lamp Switch ASSY Replacement - Front Fog Lamp and Cargo Lamp > Page 16306 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement - Rear REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the fog lamp switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the fog lamp switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16311 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16312 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16313 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16314 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16315 Hazard Warning Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16316 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16317 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16318 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16319 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16320 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16321 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16322 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16323 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16324 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16325 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16326 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16327 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16328 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16329 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16330 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16331 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16332 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16333 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16334 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16335 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16336 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16337 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16338 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16339 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16340 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16345 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16346 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16347 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16348 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16349 Headlamp Dimmer Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16350 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16351 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16352 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16353 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16354 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16355 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16356 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16357 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16358 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16359 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16360 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16361 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16362 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16363 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16364 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16365 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16366 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16367 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16368 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16369 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16370 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16371 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16372 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16373 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16374 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16380 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16381 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16382 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16383 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16384 Headlamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16385 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16386 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16387 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16388 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16389 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16390 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16391 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16392 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16393 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16394 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16395 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16396 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16397 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16398 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16399 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16400 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16401 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16402 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16403 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16404 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16405 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16406 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16407 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16408 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16409 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement Headlamp Switch: Service and Repair Headlamp Switch Replacement REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Unsnap the switch from the housing. 3. Disconnect the electrical connectors. 4. Remove the switch. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement > Page 16412 1. Connect the electrical connectors. 2. Install the headlamp switch by snapping the headlamps switch into place. 3. Install the bezel to the instrument panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement > Page 16413 Headlamp Switch: Service and Repair Headlamp Leveling Switch Replacement REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the head lamp leveling switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the head lamp leveling switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16418 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16419 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16420 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16421 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16422 Turn Signal Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16423 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16424 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16425 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16426 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16427 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16428 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16429 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16430 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16431 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16432 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16433 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16434 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16435 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16436 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16437 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16438 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16439 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16440 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16441 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16442 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16443 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16444 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16445 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16446 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16447 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Underhood Lamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16452 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16453 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16454 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16455 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16456 Underhood Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16457 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16458 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16459 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16460 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16461 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16462 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16463 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16464 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16465 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16466 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16467 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16468 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16469 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16470 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16471 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16472 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16473 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16474 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16475 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16476 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16477 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16478 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16479 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16480 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16481 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Description and Operation Spot Lamp: Description and Operation The STOP LPS 20 A fuse in the engine wiring harness junction block supplies battery positive voltage to the normally open stop lamp switch. When the driver presses the brake pedal, the switch contacts close and battery positive voltage is supplied to both the VEH STOP 10 A fuse and the CHMSL 10 A fuse. Battery positive voltage is also supplied by the STOP LPS 20 A fuse in the engine wiring harness junction block to the turn signal switch. The current flow is now to the stop lamps which are grounded at G401. The Center High Mounted Stop Lamp (CHMSL) is grounded at G410 or G203 for pick ups. For trailer wiring, a separate stop lamp circuit is connected through the engine wiring harness junction block from the CHMSL 20 A fuse to the trailer wiring harness. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Tail Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 16489 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Page 16490 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16493 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16494 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16495 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16496 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16497 Tail Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16498 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16499 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16500 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16501 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16502 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16503 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16504 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16505 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16506 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16507 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16508 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16509 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16510 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16511 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16512 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16513 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16514 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16515 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16516 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16517 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16518 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16519 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16520 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16521 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16522 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 16523 Tail Lamp: Description and Operation PARK, TAIL AND MARKER LAMPS The park, tail and marker lamps, including the license lamps, are turned on when the headlamp switch is placed in the PARK or ON position or anytime the headlights are requested. The PARK LPS 30 A fuse in the engine wiring harness junction block supplies battery positive voltage to both the park lamp relay switch contacts and the park lamp coil circuit. The Body Control Module (BCM) provides a ground or control circuit to the park lamp relay coil circuit. When the park lamps are turned on the BCM energizes the park lamp relay. Current flow is from the park lamp relay to the FR PRK 10 A fuse, RR PRK 10 A fuse LR PRK 10 A fuse, and the TRL PRK 15 A fuse, and to their respective park and marker lamps. The front park and marker lamps are grounded at G100. The rear park and marker lamps are grounded at G401. The license lamps are grounded at G401. If the headlight switch is left in the ON position, the inadvertent power control feature will turn off the park, tail and marker lamps approximately 10 minutes after the ignition switch is turned to the OFF position. If the driver places the headlight switch in the ON position after the ignition switch has been turned OFF, or if the ignition switch is in the ACCY position, the park, tail and marker lamps will remain on until turned off or the battery runs dead. The CTSY LMP 15 A fuse in the engine wiring harness junction block supplies battery positive voltage to both the inadvertent power relay switch contacts and the inadvertent power relay coil circuit. The body control module (BCM) provides a ground or control circuit to the park lamp relay coil circuit. When the driver presses the cargo lamp switch, the BCM energizes the inadvertent power relay. Current flow is from the inadvertent power relay to the cargo lamps. The cargo lamps are grounded at G203. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 16524 Tail Lamp: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 16525 Tail Lamp: Service and Repair TAIL/TURN SIGNAL LAMP REPLACEMENT REMOVAL PROCEDURE 1. Ensure that the headlamp switch is in the OFF position. 2. Open the endgate. 3. Avalanche model shown. Remove the 2 screws retaining the tail/turn signal lamp assembly to the body. 4. Identify the bulb in need of replacement. - The top bulb is a parking lamp and stop lamp - The center bulb is a turn indicator lamp - The lower bulb is a backup lamp 5. Rotate the bulb socket 1/4 turn counter-clockwise in order to remove the bulb sockets from the tail/turn lamp assembly. 6. Remove the bulbs from the sockets by pulling out the bulbs. INSTALLATION PROCEDURE 1. Install the bulb into the socket. 2. Install the bulb socket to the tail/turn lamp assembly by rotating the socket 1/4 turn clockwise. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the tail/turn signal lamp assembly to the vehicle with the 2 screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 16526 4. Close the endgate. 5. Inspect the operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16531 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16532 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16533 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16534 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16535 Trailer Lamps: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16536 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16537 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16538 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16539 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16540 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16541 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16542 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16543 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16544 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16545 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16546 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16547 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16548 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16549 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16550 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16551 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16552 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16553 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16554 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16555 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16556 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16557 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16558 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16559 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16560 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16569 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16570 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16576 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16577 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Lighting Module: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement Seat Track: All Technical Service Bulletins Interior - Loose/Unwanted Seat Movement Bulletin No.: 05-08-50-012A Date: July 24, 2006 TECHNICAL Subject: Unwanted/Loose Seat Movement (Apply Adhesive and Install New Bolts in Seat Mounting Rails) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac ESV 1999-2007 Chevrolet Silverado Pickup Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Pickup Models (Classic) 2000-2006 GMC Yukon, Yukon XL 2003-2006 HUMMER H2 with Power Driver Front Seat Power Adjuster (RPO AG1) and/or Passenger Seat Power Adjuster (RPO AG2) Supercede: This bulletin is being revised to add model years and additional Warranty Information. Please discard Corporate Bulletin Number 05-08-50-012 (Section 08 - Body and Accessories). Condition Some customers may comment on unwanted seat movement in the front power bucket seat (driver or passenger) during fast acceleration or hard braking. A metal to metal clicking noise is often heard at seat "stops." Cause The threads of the two zinc nut retainers (one on each side of the seat adjuster) may creep over time, causing a loss of self-rolling screw clamp load and ultimately causes relative rail and vehicle seat motion. Correction Apply adhesive and install new bolts in seat mounting rails using the following procedure. 1. Remove the front seat and invert onto a flat surface covered with a clean, non-scratch material (soft cloth or similar). Refer to the applicable Seats sub-section in SI. Adjust so that the seat mounting rails are at 45 degrees. 2. Remove the upper M8 mounting bolt from one rail and discard. Leave the other bolt intact as this will hold the track in place while working. Wipe the bolt hole area with a clean rag. Important: Only use the adhesive provided in the repair kit. Do not substitute with other adhesives. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Lighting Module: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement > Page 16583 3. Take one of the adhesive sachets and carefully cut the flag tip off the notched end spout in line with the notch. 4. While holding the sachet vertical, slowly dribble the adhesive into the edge of the bolt hole as shown, ensuring that the adhesive flows into the joint between the seat rail and the zinc block. DO NOT pour the adhesive down the center of the hole. The object is to let the adhesive "wick" between the zinc block and the seat rail in order to bond the two pieces together. Important: If the bolt thread strips or the proper torque cannot be achieved, then the entire seat adjuster mechanism must be replaced. 5. Replace the previous bolt with a new M8 bolt (1) (included) and install using a "click torque wrench" preset to 9 N.m (79 lb in). 6. Remove the second M8 mounting bolt from the rail and discard. 7. Repeat steps 2 through 5 for the second bolt. 8. Repeat steps 2 through 6 for the opposite mounting rail. 9. Before installing the seat into the vehicle, verify that the seat will function correctly and does not make any unusual noises during forward and rearward travel motion. 10. Install the seat. Refer to the applicable Seats sub-section of SI. 11. While sitting in the seat, verify seat function and listen for any unusual noises. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Lighting Module: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement > Page 16584 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Lighting Module: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement > Page 16590 3. Take one of the adhesive sachets and carefully cut the flag tip off the notched end spout in line with the notch. 4. While holding the sachet vertical, slowly dribble the adhesive into the edge of the bolt hole as shown, ensuring that the adhesive flows into the joint between the seat rail and the zinc block. DO NOT pour the adhesive down the center of the hole. The object is to let the adhesive "wick" between the zinc block and the seat rail in order to bond the two pieces together. Important: If the bolt thread strips or the proper torque cannot be achieved, then the entire seat adjuster mechanism must be replaced. 5. Replace the previous bolt with a new M8 bolt (1) (included) and install using a "click torque wrench" preset to 9 N.m (79 lb in). 6. Remove the second M8 mounting bolt from the rail and discard. 7. Repeat steps 2 through 5 for the second bolt. 8. Repeat steps 2 through 6 for the opposite mounting rail. 9. Before installing the seat into the vehicle, verify that the seat will function correctly and does not make any unusual noises during forward and rearward travel motion. 10. Install the seat. Refer to the applicable Seats sub-section of SI. 11. While sitting in the seat, verify seat function and listen for any unusual noises. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Lighting Module: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement > Page 16591 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions Trunk Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16596 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16597 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16598 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16599 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16600 Trunk Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16601 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16602 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16603 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16604 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16605 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16606 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16607 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16608 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16609 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16610 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16611 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16612 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16613 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16614 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16615 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16616 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16617 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16618 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16619 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16620 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16621 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16622 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16623 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16624 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16625 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions Combination Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16631 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16632 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16633 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16634 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16635 Combination Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16636 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16637 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16638 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16639 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16640 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16641 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16642 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16643 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16644 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16645 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16646 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16647 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16648 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16649 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16650 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16651 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16652 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16653 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16654 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16655 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16656 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16657 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16658 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16659 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16660 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Flasher: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16665 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16666 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16667 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16668 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16669 Turn Signal Flasher: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16670 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16671 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16672 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16673 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16674 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16675 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16676 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16677 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16678 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16679 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16680 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16681 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16682 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16683 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16684 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16685 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16686 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16687 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16688 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16689 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16690 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16691 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16692 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16693 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 16694 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Page 16695 Turn Signal Flasher: Service and Repair HAZARD AND TURN SIGNAL FLASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the knee bolster. 2. On the back side of the fuse block release the retainer while pulling the flasher (1) outwards. 3. Remove the flasher (1) from the fuse block. INSTALLATION PROCEDURE 1. Install the flasher (1) to the fuse block until the retainer clicks into place. 2. Install the knee bolster. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Turn Signal Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 16700 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 16701 Turn Signal Lamp: Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 16702 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16705 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16706 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16707 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16708 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16709 Turn Signal Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16710 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16711 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16712 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16713 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16714 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16715 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16716 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16717 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16718 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16719 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16720 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16721 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16722 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16723 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16724 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16725 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16726 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16727 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16728 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16729 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16730 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16731 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16732 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16733 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16734 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16735 Turn Signal Lamp: Connector Views Park/Turn Signal Lamp - LF Park/Turn Signal Lamp - RF Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16736 Park/Turn Signal Lamp - LR Park/Turn Signal Lamp - RR Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Page 16737 Turn Signal Lamp: Description and Operation The HAZ LP 20 A fuse in the engine wiring harness junction block supplies battery positive voltage to the hazard switch assembly. The TURN 20 A fuse in the engine wiring harness junction block supplies Ignition positive voltage to the turn signal switch assembly. With the ignition switch in the RUN or START position, ignition positive voltage is connected through the turn signal and hazard switch assembly to the flasher module which is grounded at G203. When the turn signal switch is placed in either the left or right position, the circuit is complete from the flasher module through the turn signal switch to the turn signal lamps and to ground. The flasher module then sends an on-off voltage signal through the turn signal switch to either the left or right turn signals and their Instrument Panel Cluster (IPC) indicator. The audio chime is also activated when the turn signals are on. When the hazard switch is pressed, all turn signal lamps will flash including both IPC turn indicators. The front turn signals are grounded at G100. The rear turn signals are grounded at G401. For trailer wiring, separate turn signal circuits are connected through the turn signal switch for the trailer wiring harness. The TRL L TRN 10 A fuse and TRL R TRN 10 A fuse in the engine wiring harness junction block supplies the signal for the trailer turn signal lamps. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Service and Repair > Park/Turn Signal Lamp Replacement Turn Signal Lamp: Service and Repair Park/Turn Signal Lamp Replacement REMOVAL PROCEDURE 1. Ensure the headlamp switch is in the OFF position. 2. Remove the headlamp. 3. Remove the park/turn signal lamp assembly by pushing on the inboard retainer clip. 4. Disconnect the electrical connector from the assembly. INSTALLATION PROCEDURE 1. Install the electrical connector to the park/turn signal lamp assembly. 2. Install the lamp assembly. 3. Install the headlamp. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Service and Repair > Park/Turn Signal Lamp Replacement > Page 16740 Turn Signal Lamp: Service and Repair Tail/Turn Signal Lamp Replacement REMOVAL PROCEDURE 1. Ensure that the headlamp switch is in the OFF position. 2. Open the endgate. 3. Avalanche model shown. Remove the 2 screws retaining the tail/turn signal lamp assembly to the body. 4. Identify the bulb in need of replacement. - The top bulb is a parking lamp and stop lamp - The center bulb is a turn indicator lamp - The lower bulb is a backup lamp 5. Rotate the bulb socket 1/4 turn counter-clockwise in order to remove the bulb sockets from the tail/turn lamp assembly. 6. Remove the bulbs from the sockets by pulling out the bulbs. INSTALLATION PROCEDURE 1. Install the bulb into the socket. 2. Install the bulb socket to the tail/turn lamp assembly by rotating the socket 1/4 turn clockwise. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the tail/turn signal lamp assembly to the vehicle with the 2 screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Service and Repair > Park/Turn Signal Lamp Replacement > Page 16741 4. Close the endgate. 5. Inspect the operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16746 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16747 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16748 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16749 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16750 Turn Signal Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16751 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16752 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16753 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16754 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16755 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16756 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16757 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16758 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16759 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16760 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16761 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16762 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16763 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16764 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16765 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16766 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16767 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16768 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16769 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16770 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16771 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16772 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16773 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16774 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16775 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16780 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16781 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16782 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16783 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16784 Turn Signal Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16785 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16786 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16787 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16788 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16789 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16790 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16791 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16792 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16793 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16794 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16795 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16796 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16797 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16798 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16799 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16800 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16801 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16802 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16803 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16804 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16805 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16806 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16807 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16808 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16809 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Underhood Lamp Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16815 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16816 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16817 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16818 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16819 Underhood Lamp Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16820 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16821 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16822 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16823 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16824 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16825 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16826 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16827 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16828 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16829 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16830 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16831 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16832 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16833 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16834 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16835 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16836 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16837 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16838 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16839 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16840 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16841 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16842 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16843 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16844 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > Customer Interest for Vanity Lamp: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Vanity Lamp: Customer Interest Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Bulletin No.: 06-08-42-002A Date: January 23, 2007 TECHNICAL Subject: Sunshade (Visor) Vanity Mirror Bulb Inoperative (Replace Vanity Mirror Bulb Only) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2005-2007 Cadillac STS 2001-2005 Chevrolet Impala, Monte Carlo 2001-2006 Chevrolet Silverado Crew Cab, Suburban, Tahoe 2001-2006 GMC Sierra Crew Cab, Yukon, Yukon XL 2004-2005 Pontiac Grand Prix 2006-2007 HUMMER H3 Supercede: This bulletin is being updated to add the 2007 model year. Please discard Corporate Bulletin Number 06-08-42-002 (Section 08 - Body & Accessories). Condition Some customers may comment that a sunshade (visor) vanity mirror bulb is inoperative. Cause This condition may be caused by an inoperative bulb. Correction Do NOT replace the entire sunshade (visor) assembly. Replace the sunshade (visor) vanity mirror bulb with P/N 9442395 if repairing one of the affected models covered for an inoperative vanity mirror bulb. Refer to Vanity Mirror Lamp Replacement in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > Customer Interest for Vanity Lamp: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. > Page 16853 The vanity mirror bulb can be accessed by removing the lens. Place a flat-bladed tool in the notches and gently pry out the lens. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vanity Lamp: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Vanity Lamp: All Technical Service Bulletins Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Bulletin No.: 06-08-42-002A Date: January 23, 2007 TECHNICAL Subject: Sunshade (Visor) Vanity Mirror Bulb Inoperative (Replace Vanity Mirror Bulb Only) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2005-2007 Cadillac STS 2001-2005 Chevrolet Impala, Monte Carlo 2001-2006 Chevrolet Silverado Crew Cab, Suburban, Tahoe 2001-2006 GMC Sierra Crew Cab, Yukon, Yukon XL 2004-2005 Pontiac Grand Prix 2006-2007 HUMMER H3 Supercede: This bulletin is being updated to add the 2007 model year. Please discard Corporate Bulletin Number 06-08-42-002 (Section 08 - Body & Accessories). Condition Some customers may comment that a sunshade (visor) vanity mirror bulb is inoperative. Cause This condition may be caused by an inoperative bulb. Correction Do NOT replace the entire sunshade (visor) assembly. Replace the sunshade (visor) vanity mirror bulb with P/N 9442395 if repairing one of the affected models covered for an inoperative vanity mirror bulb. Refer to Vanity Mirror Lamp Replacement in SI. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vanity Lamp: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. > Page 16859 The vanity mirror bulb can be accessed by removing the lens. Place a flat-bladed tool in the notches and gently pry out the lens. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions Vanity Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16862 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16863 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16864 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16865 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16866 Vanity Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16867 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16868 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16869 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16870 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16871 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16872 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16873 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16874 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16875 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16876 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16877 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16878 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16879 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16880 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16881 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16882 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16883 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16884 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16885 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16886 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16887 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16888 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16889 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16890 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16891 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 16892 Vanity Mirror Lamp - Left, Right Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Page 16893 Vanity Lamp: Description and Operation The inadvertent power relay provides battery positive voltage to each vanity mirror lamp. When the vanity mirror cover on the sunshade is opened, its switch closes to provide a ground circuit and the vanity lamp illuminates. The vanity lamps are grounded at G203. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations > Page 16903 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations Fuse Block - Underhood Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 16911 Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Service and Repair > Module Replacement - Rear Power Window Power Window Control Module: Service and Repair Module Replacement - Rear Power Window REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the water deflector. 3. Remove the window glass. 4. Remove the window sash. 5. Remove the glass weatherstrip. 6. Remove the module from the door. INSTALLATION PROCEDURE 1. Install the module to the door. 2. Install the glass weatherstrip. 3. Install the window sash. 4. Install the window glass. 5. Install the water deflector. 6. Install the trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Service and Repair > Module Replacement - Rear Power Window > Page 16916 Power Window Control Module: Service and Repair Module Replacement - Front Power Window REMOVAL PROCEDURE 1. Raise and support the window glass. 2. Remove the trim panel. 3. Remove the water deflector. 4. Disconnect the harness from the electric window motor assembly. 5. Remove the 2 bolts that hold the window glass to the regulator. 6. Remove the bolts from the window regulator. 7. Remove the window regulator assembly from the door by folding both sides of the window regulator assembly together. INSTALLATION PROCEDURE 1. Install the regulator to the door. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the window regulator. Tighten Tighten the bolts to 9 N.m (80 lb in). 3. Align the window glass to the regulator, and install the bolts that hold the window glass to the regulator. Tighten Tighten the bolts to 9 N.m (80 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Service and Repair > Module Replacement - Rear Power Window > Page 16917 4. Connect the harness to the electric window motor assembly. 5. Install the water deflector. 6. Install the trim panel. 7. Lower the window. Inspect the operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16924 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16925 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16926 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16927 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16928 Power Window Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16929 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16930 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16931 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16932 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16933 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16934 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16935 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16936 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16937 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16938 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16939 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16940 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16941 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16942 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16943 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16944 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16945 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16946 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16947 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16948 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16949 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16950 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16951 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16952 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16953 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16954 Power Window Switch: Connector Views Window Switch - LR/RR Window/Door Lock Switch - Driver (Except Base) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16955 Window/Door Lock Switch - Driver Connector C1 (Except Base) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16956 Window/Door Lock Switch - Driver Connector C2 (Except Base) For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16957 Window/Door Lock Switch - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement Power Window Switch: Service and Repair Power Window Switch Replacement REMOVAL PROCEDURE 1. Remove the power accessory switch panel. 2. Disconnect the power window switch electrical connector. 3. Remove the screws from the window switch. 4. Remove the switch from the switch panel by lifting the rear of the switch and sliding the switch out from the switch panel. INSTALLATION PROCEDURE 1. Install the switch to the switch panel sliding the front tabs in first. Rock the switch down in order to seat the switch completely. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the window switch. Tighten Tighten the window switch screws to 2 N.m (18 lb in). 3. Connect the electrical connector to the window switch. 4. Install the power accessory switch panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement > Page 16960 Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door REMOVAL PROCEDURE 1. Use a small flat-bladed tool in order to carefully pry the door power window switch from the door trim panel. 2. Disconnect the electrical connector from the switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the switch. 2. Install the switch to the door trim panel by pressing the switch into place until fully seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Service and Repair > Module Replacement - Rear Power Window Power Window Control Module: Service and Repair Module Replacement - Rear Power Window REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the water deflector. 3. Remove the window glass. 4. Remove the window sash. 5. Remove the glass weatherstrip. 6. Remove the module from the door. INSTALLATION PROCEDURE 1. Install the module to the door. 2. Install the glass weatherstrip. 3. Install the window sash. 4. Install the window glass. 5. Install the water deflector. 6. Install the trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Service and Repair > Module Replacement - Rear Power Window > Page 16966 Power Window Control Module: Service and Repair Module Replacement - Front Power Window REMOVAL PROCEDURE 1. Raise and support the window glass. 2. Remove the trim panel. 3. Remove the water deflector. 4. Disconnect the harness from the electric window motor assembly. 5. Remove the 2 bolts that hold the window glass to the regulator. 6. Remove the bolts from the window regulator. 7. Remove the window regulator assembly from the door by folding both sides of the window regulator assembly together. INSTALLATION PROCEDURE 1. Install the regulator to the door. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the window regulator. Tighten Tighten the bolts to 9 N.m (80 lb in). 3. Align the window glass to the regulator, and install the bolts that hold the window glass to the regulator. Tighten Tighten the bolts to 9 N.m (80 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Service and Repair > Module Replacement - Rear Power Window > Page 16967 4. Connect the harness to the electric window motor assembly. 5. Install the water deflector. 6. Install the trim panel. 7. Lower the window. Inspect the operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair REMOVAL PROCEDURE 1. Raise the window. If the window motor is inoperable, remove the glass window to gain access to the window mote retaining screws. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the door speaker. 5. Support the glass. 6. Disconnect the wiring harness from the window regulator motor. 7. Remove the 3 bolts (1) from the window motor located on the front side of the motor. IMPORTANT: Do not allow the cable gear to come out the housing. Failure will result in the cable coming off the spool. 8. Separate the motor from the cable housing by wiggling the window motor. Observe the orientation of the window motor. 9. Remove the motor from the window regulator assembly. INSTALLATION PROCEDURE 1. Install the window motor to the cable housing by wiggling it into place. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts (1) to the window regulator motor. Tighten Tighten the bolts to 5 N.m (44 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Page 16972 3. Install the glass window, if removed. 4. Connect the wiring harness to the window regulator motor. 5. Remove the window support. 6. Connect the wire connector to the switch to inspect the operation of the window. After inspection disconnect the wire harness and continue the installation. 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair Window Regulator Motor Replacement - Rear Door Removal Procedure 1. Raise the window. If the window motor is inoperable, remove the window to gain access to the window motor retaining screws. Refer to Window Replacement - Rear Door (Tahoe/Yukon/Escalade) Window Replacement - Rear Door (Suburban/Yukon XL/Avalanche/Escalade EXT). 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the door speaker. 5. Support the window. 6. Disconnect the wiring harness from the window regulator motor. 7. Remove the 3 bolts from the window motor located on the front side of the motor. Important: Do not allow the cable gear come out of the housing. A failure will result with the cable coming off the spool. 8. Separate the motor from the cable housing by wiggling the window motor. Observe the orientation of the window motor. 9. Remove the motor from the window regulator assembly. Installation Procedure 1. Install the motor to the cable housing by wiggling motor into place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts to the window motor. Tighten the bolts to 5 N.m (44 lb in). 3. Install the window, if removed. 4. Connect the wiring harness to the window regulator motor. 5. Remove the window support. 6. Connect the wire connector to the switch to inspect the operation of the window. 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16981 Electrical Symbols Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16982 Electrical Symbols Part 2 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16983 Electrical Symbols Part 3 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16984 Electrical Symbols Part 4 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16985 Power Window Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35 L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16986 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C ( 0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16987 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16988 With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground - Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity - Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the DMM. This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the DMM to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the DMM to the V (AC) or V (DC) position. 3. Press the range button of the DMM in order to select the desired voltage range. 4. Press the MIN MAX button of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions - Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED - J 42675 flatware Probe Adapter - J 38125-B Terminal Repair Kit It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16989 inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. - Using Connector Test Adapters - Probing Electrical Connectors Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16990 - Troubleshooting with a Digital Multimeter - Troubleshooting with a Test Lamp - Using Fused Jumper Wires - Measuring Voltage - Measuring Voltage Drop - Measuring Frequency - Testing for Continuity - Testing for Short to Ground - Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16991 NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16992 Fuse Types Part 1 Fuse Types Part 2 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: - Connector Position Assurance Locks - Terminal Position Assurance Locks - Push to Seat Connectors - Pull to Seat Connectors - Weather Pack Connectors - Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16993 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16994 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16995 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16996 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: - Circuit Protection - Fuses - Circuit Protection - Circuit Breakers - Circuit Protection - Fusible Links - Repairing Damaged Wire Insulation - Splicing Copper Wire Using Splice Clips - Splicing Copper Wire Using Splice Sleeves - Splicing Twisted or Shielded Cable - Splicing Inline Harness Diodes - Heated Oxygen Sensor (HO2S) Wiring Repairs Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16997 - SIR/SRS Wiring Repairs - Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16998 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16999 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17000 Wire Size Conversion 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17001 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17002 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17003 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions in order to repair the twisted/shielded cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17004 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17005 - Rewrap the conductors with the MYLAR tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with MYLAR tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17006 performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping toot - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17007 Equivalents - Decimal And Metric Part 1 Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17008 Equivalents - Decimal And Metric Part 2 Arrows and Symbols Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17009 Various symbols are used in order to describe different service operations. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17010 Conversion - English/Metric Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17011 Power Window Switch: Connector Views Window Switch - LR/RR Window/Door Lock Switch - Driver (Except Base) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17012 Window/Door Lock Switch - Driver Connector C1 (Except Base) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17013 Window/Door Lock Switch - Driver Connector C2 (Except Base) For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application ID". See: Application and ID/RPO Codes Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17014 Window/Door Lock Switch - Front Passenger Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement Power Window Switch: Service and Repair Power Window Switch Replacement REMOVAL PROCEDURE 1. Remove the power accessory switch panel. 2. Disconnect the power window switch electrical connector. 3. Remove the screws from the window switch. 4. Remove the switch from the switch panel by lifting the rear of the switch and sliding the switch out from the switch panel. INSTALLATION PROCEDURE 1. Install the switch to the switch panel sliding the front tabs in first. Rock the switch down in order to seat the switch completely. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the window switch. Tighten Tighten the window switch screws to 2 N.m (18 lb in). 3. Connect the electrical connector to the window switch. 4. Install the power accessory switch panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement > Page 17017 Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door REMOVAL PROCEDURE 1. Use a small flat-bladed tool in order to carefully pry the door power window switch from the door trim panel. 2. Disconnect the electrical connector from the switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the switch. 2. Install the switch to the door trim panel by pressing the switch into place until fully seated. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 17027 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 17028 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 17029 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 17035 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 17036 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 17037 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Latch Replacement - Removable Rear Window Back Window Glass: Service and Repair Latch Replacement - Removable Rear Window Latch Replacement - Removable Rear Window Removal Procedure 1. Remove the removable window panel. 2. Remove the trim panel (1) along the rear of the headliner. 3. Remove the latch retaining bolts. 4. Disconnect the electrical connector (2) from the latch. 5. Remove the latch from the vehicle. Installation Procedure 1. Connect the electrical connector (2) to the latch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the latch retaining bolts. Tighten the bolts to 9 N.m (80 lb in). 3. Install the trim panel (1). 4. Install the removable window panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Latch Replacement - Removable Rear Window > Page 17049 Back Window Glass: Service and Repair Rear Window Replacement Rear Window Replacement Tools Required * J 24402-A Glass Sealant Cold Knife Remover * J 39032 Stationary Glass Removal Tool * J 34940 Rivet Gun * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Commercial-type Utility Knife * Razor Blade Scraper * Suction Cups * Plastic Paddle Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: Before cutting out a window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Remove the window garnish molding from the door frame. 2. Disconnect the electrical connector from the window defogger, if equipped. Caution: Refer to Cracked Window Caution in Service Precautions. Important: Keep the cutting edge of the tool against the rear window. This will allow the urethane adhesive to be separated from the window. 3. Use J 24402-A, J 39032, or equivalent in order to remove the rear window. * Leave a base of urethane on the pinchweld flange. * The only suitable lubrication is clear water. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Latch Replacement - Removable Rear Window > Page 17050 4. With the aid of an assistant, remove the window from the opening. Installation Procedure 1. Install the stationary window into the opening 2. Connect the electrical connector to the window defogger, if equipped. 3. Install the window garnish molding to the door frame. 4. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Corner Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window Front Door Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Window REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the window. 4. Remove the screws. 5. Pull the weatherstrip from the following locations: ^ The front of the glass run channel ^ The top of the window frame flange ^ The rear of the glass run channel 6. Remove the weatherstrip from the door. INSTALLATION PROCEDURE 1. Install the weatherstrip to the following locations: ^ The front of the glass run channel ^ The top of the window frame flange ^ The rear of the glass run channel NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts. Tighten Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 17060 Tighten the bolts to 6 N.m (53 lb in). 3. Install the window. 4. Install the water deflector. 5. Install the door trim panel. 6. Inspect the operation of the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 17061 Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel REMOVAL PROCEDURE 1. Remove the window. 2. Remove the window glass weatherstrip. 3. Remove the window run channel bolts. 4. Remove the front and the rear window run channels from the door INSTALLATION PROCEDURE 1. Install the front and the rear window run channels to the door. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the front and the rear window run channel bolts. Tighten 2.1. Tighten the front bolt to 9 N.m (80 lb in). 2.2. Tighten the rear bolt to 9 N.m (80 lb in). 3. Install the window glass weatherstrip. 4. Install the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 17062 Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Front Door Window Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the window. 4. Remove the screws. 5. Pull the weatherstrip from the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel 6. Remove the weatherstrip from the door. Installation Procedure 1. Install the weatherstrip to the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts. Tighten the bolts to 6 N.m (53 lb in). 3. Install the window. 4. Install the water deflector. 5. Install the door trim panel. 6. Inspect the operation of the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Window > Page 17063 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Outer - Front Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outside mirror. 3. Remove the outer sealing strip from the door, lifting up on the forward end in order to unhook the rear of the strip from the window run channel. Installation Procedure 1. Hook the rear end of the sealing strip into the window run channel. Lower and press the strip into place. 2. Install the outside mirror. 3. Raise the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Window Replacement Liftgate Window Glass: Service and Repair Liftgate Window Replacement REMOVAL PROCEDURE 1. Open the liftgate window. 2. Support the liftgate window. 3. Disconnect the window defogger electrical connectors, if equipped. 4. Remove the liftgate window struts. 5. Open the liftgate in order to expose the liftgate window hinges. 6. With an assistant, remove the liftgate window hinge pin retainers from the hinge pins. 7. With an assistant, remove the liftgate window from the liftgate by sliding to the left. INSTALLATION PROCEDURE 1. Close the liftgate. 2. With an assistant, install the liftgate window to the liftgate by locating on pins and sliding to the right. 3. Open the liftgate. 4. With an assistant, install the new liftgate window hinge pin retainers. 5. Close the liftgate and open and support liftgate window. 6. Install the liftgate window struts. 7. Connect the liftgate window defogger electrical connectors, if equipped. 8. Remove the support and close window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Window Replacement > Page 17068 Liftgate Window Glass: Service and Repair Lift Window Panel Replacement Rear Lift Window Replacement Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Close the liftgate before removing the liftgate window. 2. Open the liftgate window. 3. Disconnect the rear defogger plug from the liftgate window. 4. Remove the struts from the liftgate window. Caution: Refer to Cracked Window Caution in Service Precautions. 5. With the aid of an assistant remove the window (1) from the closed liftgate. Remove the C-clips from the liftgate window hinges, NOT from the liftgate. 6. Slide the liftgate window toward the left of the vehicle and lift off. Installation Procedure Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Window Replacement > Page 17069 1. With the aid of an assistant install the liftgate window (1) to the vehicle. 2. Install the C-clips to the liftgate window hinges. 3. Install the struts to the liftgate window. 4. Connect the rear defogger plug to the liftgate window. 5. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 6. Close the liftgate window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Stationary Quarter Window Replacement Quarter Window Glass: Service and Repair Stationary Quarter Window Replacement TOOLS REQUIRED ^ J 24402-A Glass Sealant Cold Knife Remover ^ J 39032 Stationary Glass Removal Tool ^ J 34940 Rivet Gun ^ Urethane Adhesive Kit GM P/N 12346392 or Equivalent ^ Isopropyl Alcohol or Equivalent ^ Cartridge-type Caulking Gun ^ Commercial-type Utility Knife ^ Razor Blade Scraper ^ Suction Cups ^ Plastic Paddle REMOVAL PROCEDURE CAUTION: ^ Refer to Glass and Sheet Metal Handling Caution in Service Precautions. ^ Refer to Cracked Window Caution in Service Precautions. IMPORTANT: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Open the liftgate. CAUTION: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury. 2. Cover the following parts to protect from broken glass. 2.1. The upper dash pad 2.2. The defroster outlets and A/C outlets 2.3. The seats and the carpeting 3. Remove the right of left side applique. IMPORTANT: Keep the cutting edge of the tool against the quarter window from inside the vehicle. This will allow the urethane adhesive to be separated from the window. 4. Use J 24402-A, J 39032, or equivalent in order to remove the quarter window. ^ Leave a base of urethane on the pinchweld flange. ^ The only suitable lubrication is clear water. 5. If the original reveal molding on the window is damaged, replace the molding. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Stationary Quarter Window Replacement > Page 17076 6. With the aid of an assistant, use the suction cups to remove the window from the opening. INSTALLATION PROCEDURE 1. install the quarter window into the opening. 2. Install the right of left side applique. 3. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 4. Close the liftgate window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Stationary Quarter Window Replacement > Page 17077 Quarter Window Glass: Service and Repair Quarter Window Replacement (Non Encapsulated) Quarter Window Replacement Tools Required * J 24402-A Glass Sealant Cold Knife Remover * J 39032 Stationary Glass Removal Tool * J 34940 Rivet Gun * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Commercial-type Utility Knife * Razor Blade Scraper * Suction Cups * Plastic Paddle Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Caution: Refer to Cracked Window Caution in Service Precautions. Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Open the liftgate. Caution: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury. 2. Cover the following parts to protect from broken glass. 1. The upper dash pad 2. The defroster outlets and A/C outlets 3. The seats and the carpeting 3. Remove the right of left side applique. Important: Keep the cutting edge of the tool against the quarter window from inside the vehicle. This will allow the urethane adhesive to be separated from the window. 4. Use J 24402-A, J 39032, or equivalent in order to remove the quarter window. * Leave a base of urethane on the pinchweld flange. * The only suitable lubrication is clear water. 5. If the original reveal molding on the window is damaged, replace the molding. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Stationary Quarter Window Replacement > Page 17078 6. With the aid of an assistant, use the suction cups to remove the window from the opening. Installation Procedure 1. Install the quarter window into the opening. 2. Install the right of left side applique. 3. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 4. Close the liftgate window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window Rear Door Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Window REMOVAL PROCEDURE 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. INSTALLATION PROCEDURE 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 17084 Rear Door Window Glass Weatherstrip: Service and Repair Sealing Strip Replacement - Rear Door Window Belt Outer REMOVAL PROCEDURE IMPORTANT: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outer sealing strip from the door. INSTALLATION PROCEDURE 1. Align the sealing strip in place. Lower and press the strip into place. 2. Raise the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 17085 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Channel REMOVAL PROCEDURE 1. Remove the window. 2. Remove the window glass weatherstrip. 3. Remove the front window run channel top bolt. 4. Remove the front window run channel from the door. INSTALLATION PROCEDURE 1. Install the front window run channel to the door. 2. Install the front window run channel top bolt. Do not tighten the bolt 3. Install the window glass weatherstrip. 4. Install the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 17086 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. Installation Procedure 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Window > Page 17087 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Rear Door Window Belt Outer Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outer sealing strip from the door. Installation Procedure 1. Align the sealing strip in place. Lower and press the strip into place. 2. Raise the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Handle > Component Information > Service and Repair Window Handle: Service and Repair Window Handle Replacement Tools Required J 9886-01 Door Handle Clip Remover Removal Procedure 1. Open the door. 2. Remove the window crank handle using the J 9886-01. Be sure to retain the retainer clip on the back side of the handle. Installation Procedure 1. Install the window crank handle by pushing the handle into place. Ensure that the retainer engages. 2. Inspect the operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Front Door Module Replacement Front Door Window Regulator: Service and Repair Front Door Module Replacement Module Replacement - Front Power Window Removal Procedure 1. Raise and support the window glass. 2. Remove the trim panel. 3. Remove the water deflector. 4. Disconnect the harness from the electric window motor assembly. 5. Remove the 2 bolts that hold the window glass to the regulator. 6. Remove the bolts from the window regulator. 7. Remove the window regulator assembly from the door by folding both sides of the window regulator assembly together. Installation Procedure 1. Install the regulator to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the window regulator. Tighten Tighten the bolts to 9 N.m (80 lb in). 3. Align the window glass to the regulator, and install the bolts that hold the window glass to the regulator. Tighten Tighten the bolts to 9 N.m (80 lb in). 4. Connect the harness to the electric window motor assembly. 5. Install the water deflector. 6. Install the trim panel. 7. Lower the window. Inspect the operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Front Door Module Replacement > Page 17096 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Motor Replacement Window Regulator Motor Replacement - Front Door Removal Procedure 1. Raise the window. If the window motor is inoperable, remove the glass window to gain access to the window motor retaining screws. Refer to Window Replacement - Front Door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the door speaker. 5. Support the glass. 6. Disconnect the wiring harness from the window regulator motor. 7. Remove the 3 bolts (1) from the window motor located on the front side of the motor. Important: Do not allow the cable gear to come out of the housing. Failure will result in the cable coming off the spool. 8. Separate the motor from the cable housing by wiggling the window motor. Observe the orientation of the window motor. 9. Remove the motor from the window regulator assembly. Installation Procedure 1. Install the window motor to the cable housing by wiggling it into place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts (1) to the window regulator motor. Tighten Tighten the bolts to 5 N.m (44 lb in). 3. Install the glass window, if removed. 4. Connect the wiring harness to the window regulator motor. 5. Remove the window support. 6. Connect the wire connector to the switch to inspect the operation of the window. After inspection disconnect the wire harness and continue the installation. 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Side Door Window Module Replacement Rear Door Window Regulator: Service and Repair Rear Side Door Window Module Replacement Module Replacement - Rear Power Window (Suburban/Yukon XL/Avalanche/Escalade EXT) Removal Procedure 1. Remove the trim panel. 2. Remove the water deflector. 3. Remove the Window glass. 4. Remove the window sash. 5. Remove the glass weatherstrip. 6. Remove the module from the door. Installation Procedure 1. Install the module to the door. 2. Install the glass weatherstrip. 3. Install the window sash. 4. Install the window glass. 5. Install the water deflector. 6. Install the trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Side Door Window Module Replacement > Page 17101 Rear Door Window Regulator: Service and Repair Window Regulator Motor Replacement - Rear Door Window Regulator Motor Replacement - Rear Door Removal Procedure 1. Raise the window. If the window motor is inoperable, remove the window to gain access to the window motor retaining screws. Refer to Window Replacement - Rear Door (Tahoe/Yukon/Escalade) Window Replacement - Rear Door (Suburban/Yukon XL/Avalanche/Escalade EXT). 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the door speaker. 5. Support the window. 6. Disconnect the wiring harness from the window regulator motor. 7. Remove the 3 bolts from the window motor located on the front side of the motor. Important: Do not allow the cable gear come out of the housing. A failure will result with the cable coming off the spool. 8. Separate the motor from the cable housing by wiggling the window motor. Observe the orientation of the window motor. 9. Remove the motor from the window regulator assembly. Installation Procedure 1. Install the motor to the cable housing by wiggling motor into place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts to the window motor. Tighten the bolts to 5 N.m (44 lb in). 3. Install the window, if removed. 4. Connect the wiring harness to the window regulator motor. 5. Remove the window support. 6. Connect the wire connector to the switch to inspect the operation of the window. 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Window Run Channel Replacement - Front Door Window Track: Service and Repair Window Run Channel Replacement - Front Door Window Run Channel Replacement - Front Door Removal Procedure 1. Remove the window. 2. Remove the window glass weatherstrip. 3. Remove the window run channel bolts. 4. Remove the front and the rear window run channels from the door. Installation Procedure 1. Install the front and the rear window run channels to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front and the rear window run channel bolts. 1. Tighten the front bolt to 9 N.m (80 lb in). 2. Tighten the rear bolt to 9 N.m (80 lb in). 3. Install the window glass weatherstrip. 4. Install the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Window Run Channel Replacement - Front Door > Page 17106 Window Track: Service and Repair Window Run Channel Replacement - Rear Door Window Run Channel Replacement - Rear Door Removal Procedure 1. Remove the window. 2. Remove the window glass weatherstrip. 3. Remove the front window run channel top bolt. 4. Remove the front window run channel from the door. Installation Procedure 1. Install the front window run channel to the door. 2. Install the front window run channel top bolt. Do not tighten the bolt. 3. Install the window glass weatherstrip. 4. Install the window. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair Windshield Moulding / Trim: Service and Repair Stationary Window Reveal Molding Repair Stationary Window Reveal Molding Repair Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: The window reveal molding fills the cavity between the body and window. If the reveal molding is stretched or damaged, it cannot be reused and it must be replaced. 1. Lift up on the loose area of the reveal molding. 2. Clean the top edge of the window surface and the reveal molding with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint-free cloth. 3. If the reveal molding cannot be reused, refer to Urethane Adhesive Installation of Stationary Windows. Installation Procedure Caution: Refer to Window Retention Caution in Service Precautions. 1. Verify all primers and urethane adhesive are within expiration dates. Important: Use care when applying the prep, clear #1, to the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly. 2. Use a new dauber in order to apply glass prep, clear #1, to the channel area approximately 13 mm (1/2 in) to the upper edge of the window. 3. Wipe the glass primed area immediately with a clean lint-free cloth. 4. Shake the glass primer, black #2, for at least 1 minute. 5. Use a new dauber in order to apply glass primer, black #2, to the top edge of the window. 6. Apply a small bead of urethane adhesive (2) between the window (1) and the pinch-weld. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 17112 7. Reinstall the window reveal molding. 1. Start from the loose area and hand-press the reveal molding into place over the edge of the window. 2. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. 3. Tape should be applied in order to retain the reveal molding to the window. This will maintain a flush fit with the body. 4. The tape is to be removed after 6 hours. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 17113 Windshield Moulding / Trim: Service and Repair Windshield Side Reveal Molding Replacement Windshield Side Reveal Molding Replacement Removal Procedure 1. Pull back the front door sealing weatherstrip (1) to expose the windshield reveal molding screws. 2. Remove the screws from the windshield reveal molding. 3. Remove the windshield reveal molding from the windshield pillar. Installation Procedure 1. Install the windshield reveal molding to the windshield pillar. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the windshield reveal molding. Tighten the screws to the windshield reveal molding to 2 N.m (18 lb in). 3. Install the front door sealing weatherstrip (1) to the pinch-weld. 4. Close the door. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 17114 Windshield Moulding / Trim: Service and Repair Windshield Upper Reveal Molding Replacement Windshield Upper Reveal Molding Replacement Tools Required * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Plastic Paddle Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. 1. Remove both right and left sides of the reveal molding. Important: The windshield reveal molding fills the cavities between the body and windshield. If the reveal molding is stretched or damaged, replace the molding. 2. Remove the upper windshield reveal molding. 1. Use a flat-bladed tool in order to carefully pry the end of the upper reveal molding out about 76 mm (3 in). 2. Grasp the corner of the windshield reveal molding by hand or use a suitable tool to slowly pull the molding away from the windshield. 3. If the molding will not release, use a utility knife to release the molding. Installation Procedure 1. Clean the top edge of the windshield surface with a 50/50 mixture of isopropyl alcohol and water on a dampened lint-free cloth. 2. Fit the new reveal molding to the windshield prior to installation. Caution: Refer to Window Retention Caution in Service Precautions. 3. Verify that all primers and urethane adhesive are within expiration dates. Important: Apply the prep (clear #1) to the windshield carefully. The primer dries almost instantly, and may stain the viewing area of the windshield if not applied evenly. 4. Use a new dauber in order to apply glass prep (clear #1) to the channel area approximately 13 mm (1/2 in) to the upper edge of the windshield. 5. Wipe the glass primed area immediately with a clean lint-free cloth. 6. Shake the glass primer (black #2) for at least 1 minute. Use a new dauber to apply the primer to the top edge of the windshield. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 17115 7. Apply a small bead of urethane adhesive (2) between the windshield (1) and the pinchweld. 8. Install the upper reveal molding. 1. Start from the center and hand-press the reveal molding into place over the edge of the windshield. 2. Install the right and the left sides of the reveal molding. 3. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. 4. Apply the tape in order to retain the reveal molding to the windshield. This will maintain a flush fit with the body. 5. Remove the tape after 6 hours. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical Service Bulletins > Customer Interest for Check Valve: > 03-08-43-002A > Sep > 04 > Wipers/Washers - Rear Window Spray Nozzle Dripping Check Valve: Customer Interest Wipers/Washers - Rear Window Spray Nozzle Dripping File In Section: 08 - Body and Accessories Bulletin No.: 03-08-43-002A Date: September, 2004 TECHNICAL Subject: Rear Window Washer Spray Nozzle Drips Leaving Stain On Rear Bumper Step Cover (Install Additional Rear Window Washer Check Valve and Apply Conditioner to Rear Bumper Cover) Models: 2002-2004 Cadillac Escalade 2003-2004 Cadillac Escalade ESV 2000-2004 Chevrolet Suburban, Tahoe 2000-2004 GMC Yukon, Yukon XL This bulletin is being revised to update the repair procedure and add warranty information. Please discard Corporate Bulletin Number 03-08-43-002 (Section 08 - Body and Accessories). Condition Some customers may comment on the rear window washer spray nozzle dripping and leaving a stain on the rear bumper step cover. Cause The location of the existing rear window washer check valve along with thermal expansion of the valve may be the cause of this condition. Correction Follow the service procedure below to add an additional check valve to the rear window washer hose where it passes through the lift gate sheet metal. 1. Remove the lift gate garnish molding. 1.1. Open the lift gate window. 1.2. Remove the pushpin retainers from the garnish molding. 1.3. Pry gently with a thin-bladed tool in order to release the retaining clips. 1.4. Remove the garnish molding. 2. Remove the lift gate trim panel. 2.1. Remove the pull strap. 2.2. Pry gently with a thin-bladed tool in order to release the retaining clips. 2.3. Slide the trim panel upward to disengage the mounting hooks. 2.4. Remove the trim panel from the lift gate. 3. Locate and remove the straight connector that connects the washer hose to the pass through grommet on the lift gate sheet metal. Discard the straight connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical Service Bulletins > Customer Interest for Check Valve: > 03-08-43-002A > Sep > 04 > Wipers/Washers - Rear Window Spray Nozzle Dripping > Page 17125 4. Install the new washer check valve (1), P/N 22102237, in place of the straight connector. Install with the arrow pointing in the direction of fluid flow. 5. Install the lift gate trim panel. 5.1. Position the trim panel to the lift gate. 5.2. Slide the trim panel downward to engage the mounting hooks. 5.3. Press on the trim panel in order to engage the retaining clips. 5.4. Install the pull strap. 6. Install the lift gate garnish molding. 6.1. Install the molding to the lift gate. 6.2. Press on the molding in order to engage the retaining clips. 6.3. Install the pushpin retainers into the garnish molding. 6.4. Close the lift gate window. Caution: This product should be used in a well ventilated area using nitrile gloves and proper eye protection. This product is flammable, do not use around open flames. These reconditioning wipes may spontaneously combust, be aware of the risk. All personnel should read the Material Safety Data Sheet before using this product. Proper disposal of used wipes should be followed. Important: Make certain that the surface is clean and dry before applying Armor-Dillo. This product will not bond to wet surfaces and, if the surface is not clean, the results will not meet expectations. 7. Apply Armor-Dillo following the procedure below. 7.1 Wash the vehicle with a general purpose cleaner to make certain the surface is clean. 7.2. For ease of clean-up, tape off the painted or chrome bumper surface around step cover and remove the license plate if necessary. 7.3. Apply Armor-Dillo evenly over the surface. 7.4. Allow the product to remain on the surface for a few minutes. Important: If this step is not performed, this product will remain tacky and will attract dirt. 7.5. Use a damp lint free towel and wipe the treated surface thoroughly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical Service Bulletins > Customer Interest for Check Valve: > 03-08-43-002A > Sep > 04 > Wipers/Washers - Rear Window Spray Nozzle Dripping > Page 17126 7.6. A second coat may be needed on severely stained surface and can be applied after Step # 4. Parts Information Warranty Information Important: Please advise the customer that this is a one-time warranty repair and that future coatings are the responsibility of the owner. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Check Valve: > 03-08-43-002A > Sep > 04 > Wipers/Washers - Rear Window Spray Nozzle Dripping Check Valve: All Technical Service Bulletins Wipers/Washers - Rear Window Spray Nozzle Dripping File In Section: 08 - Body and Accessories Bulletin No.: 03-08-43-002A Date: September, 2004 TECHNICAL Subject: Rear Window Washer Spray Nozzle Drips Leaving Stain On Rear Bumper Step Cover (Install Additional Rear Window Washer Check Valve and Apply Conditioner to Rear Bumper Cover) Models: 2002-2004 Cadillac Escalade 2003-2004 Cadillac Escalade ESV 2000-2004 Chevrolet Suburban, Tahoe 2000-2004 GMC Yukon, Yukon XL This bulletin is being revised to update the repair procedure and add warranty information. Please discard Corporate Bulletin Number 03-08-43-002 (Section 08 - Body and Accessories). Condition Some customers may comment on the rear window washer spray nozzle dripping and leaving a stain on the rear bumper step cover. Cause The location of the existing rear window washer check valve along with thermal expansion of the valve may be the cause of this condition. Correction Follow the service procedure below to add an additional check valve to the rear window washer hose where it passes through the lift gate sheet metal. 1. Remove the lift gate garnish molding. 1.1. Open the lift gate window. 1.2. Remove the pushpin retainers from the garnish molding. 1.3. Pry gently with a thin-bladed tool in order to release the retaining clips. 1.4. Remove the garnish molding. 2. Remove the lift gate trim panel. 2.1. Remove the pull strap. 2.2. Pry gently with a thin-bladed tool in order to release the retaining clips. 2.3. Slide the trim panel upward to disengage the mounting hooks. 2.4. Remove the trim panel from the lift gate. 3. Locate and remove the straight connector that connects the washer hose to the pass through grommet on the lift gate sheet metal. Discard the straight connector. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Check Valve: > 03-08-43-002A > Sep > 04 > Wipers/Washers - Rear Window Spray Nozzle Dripping > Page 17132 4. Install the new washer check valve (1), P/N 22102237, in place of the straight connector. Install with the arrow pointing in the direction of fluid flow. 5. Install the lift gate trim panel. 5.1. Position the trim panel to the lift gate. 5.2. Slide the trim panel downward to engage the mounting hooks. 5.3. Press on the trim panel in order to engage the retaining clips. 5.4. Install the pull strap. 6. Install the lift gate garnish molding. 6.1. Install the molding to the lift gate. 6.2. Press on the molding in order to engage the retaining clips. 6.3. Install the pushpin retainers into the garnish molding. 6.4. Close the lift gate window. Caution: This product should be used in a well ventilated area using nitrile gloves and proper eye protection. This product is flammable, do not use around open flames. These reconditioning wipes may spontaneously combust, be aware of the risk. All personnel should read the Material Safety Data Sheet before using this product. Proper disposal of used wipes should be followed. Important: Make certain that the surface is clean and dry before applying Armor-Dillo. This product will not bond to wet surfaces and, if the surface is not clean, the results will not meet expectations. 7. Apply Armor-Dillo following the procedure below. 7.1 Wash the vehicle with a general purpose cleaner to make certain the surface is clean. 7.2. For ease of clean-up, tape off the painted or chrome bumper surface around step cover and remove the license plate if necessary. 7.3. Apply Armor-Dillo evenly over the surface. 7.4. Allow the product to remain on the surface for a few minutes. Important: If this step is not performed, this product will remain tacky and will attract dirt. 7.5. Use a damp lint free towel and wipe the treated surface thoroughly. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Check Valve: > 03-08-43-002A > Sep > 04 > Wipers/Washers - Rear Window Spray Nozzle Dripping > Page 17133 7.6. A second coat may be needed on severely stained surface and can be applied after Step # 4. Parts Information Warranty Information Important: Please advise the customer that this is a one-time warranty repair and that future coatings are the responsibility of the owner. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams Rear Wiper/Washer Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 17141 Rear Wiper/Washer And Fog Lamp Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 17145 Rear Wiper/Washer And Fog Lamp Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation Washer Fluid Level Indicator: Description and Operation LOW WASHER FLUID INDICATOR The low washer fluid indicator is controlled by the instrument panel cluster using an input from the washer fluid level switch. The washer fluid level signal circuit is supplied ignition voltage through a resistor then monitored within the instrument cluster. The washer fluid level switch is normally open so the instrument cluster detects ignition voltage on the washer fluid level signal circuit whenever the washer fluid level is not low. When the washer fluid level reaches the point where the driver should be informed that the washer fluid is low, the washer fluid level switch closes. When the washer fluid level switch is closed the washer fluid level signal circuit voltage is pulled low, and the instrument cluster illuminates the LOW WASHER FLUID indicator. In order to prevent the LOW WASHER FLUID indicator from flashing due to sloshing in the washer fluid container, the instrument cluster is programed with a 1 minute delay before changing states of the LOW WASHER FLUID indicator during an ignition cycle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams Rear Wiper/Washer Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Technical Service Bulletins > Customer Interest for Windshield Washer Pump: > 02-08-43-001A > Mar > 04 > Wipers - Rear Wiper Jumps When Turning Fog Lamps ON Windshield Washer Pump: Customer Interest Wipers - Rear Wiper Jumps When Turning Fog Lamps ON Bulletin No.: 02-08-43-001A Date: March 24, 2004 TECHNICAL Subject: Rear Wiper Jumps When Fog Lamps Turned On (Connect Auxiliary Ground to Rear Washer Pump) Models: 2002-2004 Cadillac Escalade 2003-2004 Cadillac Escalade ESV 2000-2004 Chevrolet Suburban, Tahoe 2000-2004 GMC Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add models, model years and revise the Parts Information. Please discard Corporate Bulletin Number 02-08-43-001 (Section 08 - Body and Accessories). Condition Some customers may comment that the rear wiper jumps when the fog lamps are turned on. Cause Electrical feedback from the fog lamp circuit into the ground of the rear window washer pump may cause this condition. Correction To perform this correction, you will need to obtain the following items: ^ A J 38125-B Terminal Repair Kit. Obtain the following parts from the kit. - P/N 12041351 (Cable Seal) from tray # 2 - P/N 12077411 (Terminal) from tray # 2 - P/N 12103507 (Ring Terminal) from tray # 18 ^ A 508 mm (20 in) length of Black, 0.5 mm (20 gauge) or 0.8 mm (18 gauge) wire Important: Do not re-use the old cable seals. Replace old cable seals with P/N 12041351. Isolate the rear washer pump ground circuit by performing the following steps. 1. Remove the left side fender to radiator tie bar diagonal brace. 2. Remove the battery. 3. Remove the battery tray. 4. Remove the bolt that secures the washer bottle to the upper radiator tie bar. 5. Raise the vehicle on a hoist. 6. Remove the lower washer bottle mounting bolt. 7. Locate the rear washer pump motor, mounted into the washer solvent bottle under the hood, and disconnect the wiring connector for the rear washer pump (Dark Green/White stripe and Black wires). 8. Remove the black wire from the connector. Cut the wire and tape the end to seal out moisture intrusion. A non-sealed wire will allow moisture to Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Technical Service Bulletins > Customer Interest for Windshield Washer Pump: > 02-08-43-001A > Mar > 04 > Wipers - Rear Wiper Jumps When Turning Fog Lamps ON > Page 17160 wick up the strands of the wire and may corrode other components/connections. 9. Slide one end of the new wire through the weather pack seal that was removed from the old wire. 10. Properly attach the 12077411 terminal (crimp and solder) to one end of the new black wire. 11. Properly attach a 12103507 ring terminal (crimp and solder) to the other end of the new black wire. 12. Place the new terminal and wire assembly into the rear washer pump connector and properly position the weather pack seal. 13. Reconnect the connector to the rear washer pump. 14. Route the new black wire down to the attaching point on the frame, same location as the battery ground. Follow the battery cable routing. 15. Remove the ground to frame attaching bolt. 16. Clean the battery cable and G100 ring terminals of contamination. 17. Install the new wire ring terminal between the battery ground wire (5) and the existing G100 ground wire (3). Tighten Tighten the engine wiring harness ground/negative cable bolt to 25 N.m (18 lb ft). 18. Install the lower washer bottle retaining bolt. Tighten Tighten the bolt to 9 N.m (80 lb in). 19. Lower the vehicle. 20. Install the upper washer bottle retaining bolt. Tighten Tighten the bolt to 9 N.m (80 lb in). 21. Install the battery tray. Tighten Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Technical Service Bulletins > Customer Interest for Windshield Washer Pump: > 02-08-43-001A > Mar > 04 > Wipers - Rear Wiper Jumps When Turning Fog Lamps ON > Page 17161 Tighten the battery tray bolts to 9 N.m (80 lb in). 22. Install the battery. Tighten Tighten the battery hold-down retainer bolt to 25 N.m (18 lb ft). 23. Connect the battery cables. Tighten Tighten the battery cable bolts to 17 N.m (13 lb ft). 24. Install the left side tender to radiator tie bar diagonal brace. Tighten Tighten the front end diagonal brace bolts to 9 N.m (80 lb in). 25. Reset the clock. 26. Advise the customer that all memory modules will have to be reset such as seat, radio presets, and the like. 27. Also advise the customer that the transmission shift points may feel somewhat different. This will change over a short period of time as the transmission adapts to the customer driving habits. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Washer Pump: > 02-08-43-001A > Mar > 04 > Wipers - Rear Wiper Jumps When Turning Fog Lamps ON Windshield Washer Pump: All Technical Service Bulletins Wipers - Rear Wiper Jumps When Turning Fog Lamps ON Bulletin No.: 02-08-43-001A Date: March 24, 2004 TECHNICAL Subject: Rear Wiper Jumps When Fog Lamps Turned On (Connect Auxiliary Ground to Rear Washer Pump) Models: 2002-2004 Cadillac Escalade 2003-2004 Cadillac Escalade ESV 2000-2004 Chevrolet Suburban, Tahoe 2000-2004 GMC Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add models, model years and revise the Parts Information. Please discard Corporate Bulletin Number 02-08-43-001 (Section 08 - Body and Accessories). Condition Some customers may comment that the rear wiper jumps when the fog lamps are turned on. Cause Electrical feedback from the fog lamp circuit into the ground of the rear window washer pump may cause this condition. Correction To perform this correction, you will need to obtain the following items: ^ A J 38125-B Terminal Repair Kit. Obtain the following parts from the kit. - P/N 12041351 (Cable Seal) from tray # 2 - P/N 12077411 (Terminal) from tray # 2 - P/N 12103507 (Ring Terminal) from tray # 18 ^ A 508 mm (20 in) length of Black, 0.5 mm (20 gauge) or 0.8 mm (18 gauge) wire Important: Do not re-use the old cable seals. Replace old cable seals with P/N 12041351. Isolate the rear washer pump ground circuit by performing the following steps. 1. Remove the left side fender to radiator tie bar diagonal brace. 2. Remove the battery. 3. Remove the battery tray. 4. Remove the bolt that secures the washer bottle to the upper radiator tie bar. 5. Raise the vehicle on a hoist. 6. Remove the lower washer bottle mounting bolt. 7. Locate the rear washer pump motor, mounted into the washer solvent bottle under the hood, and disconnect the wiring connector for the rear washer pump (Dark Green/White stripe and Black wires). 8. Remove the black wire from the connector. Cut the wire and tape the end to seal out moisture intrusion. A non-sealed wire will allow moisture to Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Washer Pump: > 02-08-43-001A > Mar > 04 > Wipers - Rear Wiper Jumps When Turning Fog Lamps ON > Page 17167 wick up the strands of the wire and may corrode other components/connections. 9. Slide one end of the new wire through the weather pack seal that was removed from the old wire. 10. Properly attach the 12077411 terminal (crimp and solder) to one end of the new black wire. 11. Properly attach a 12103507 ring terminal (crimp and solder) to the other end of the new black wire. 12. Place the new terminal and wire assembly into the rear washer pump connector and properly position the weather pack seal. 13. Reconnect the connector to the rear washer pump. 14. Route the new black wire down to the attaching point on the frame, same location as the battery ground. Follow the battery cable routing. 15. Remove the ground to frame attaching bolt. 16. Clean the battery cable and G100 ring terminals of contamination. 17. Install the new wire ring terminal between the battery ground wire (5) and the existing G100 ground wire (3). Tighten Tighten the engine wiring harness ground/negative cable bolt to 25 N.m (18 lb ft). 18. Install the lower washer bottle retaining bolt. Tighten Tighten the bolt to 9 N.m (80 lb in). 19. Lower the vehicle. 20. Install the upper washer bottle retaining bolt. Tighten Tighten the bolt to 9 N.m (80 lb in). 21. Install the battery tray. Tighten Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Washer Pump: > 02-08-43-001A > Mar > 04 > Wipers - Rear Wiper Jumps When Turning Fog Lamps ON > Page 17168 Tighten the battery tray bolts to 9 N.m (80 lb in). 22. Install the battery. Tighten Tighten the battery hold-down retainer bolt to 25 N.m (18 lb ft). 23. Connect the battery cables. Tighten Tighten the battery cable bolts to 17 N.m (13 lb ft). 24. Install the left side tender to radiator tie bar diagonal brace. Tighten Tighten the front end diagonal brace bolts to 9 N.m (80 lb in). 25. Reset the clock. 26. Advise the customer that all memory modules will have to be reset such as seat, radio presets, and the like. 27. Also advise the customer that the transmission shift points may feel somewhat different. This will change over a short period of time as the transmission adapts to the customer driving habits. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Technical Service Bulletins > Page 17169 Windshield Washer Pump: Diagrams Windshield Washer Fluid Pump Window Washer Pump - Rear Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Washer Pump/Reservoir Replacement Windshield Washer Pump: Service and Repair Washer Pump/Reservoir Replacement REMOVAL PROCEDURE 1. Remove the battery and battery tray from the vehicle. 2. Remove the inner wheel housing from the vehicle. 3. Disconnect the electrical connector from the washer pump. 4. Disconnect the electrical connector from the washer solvent level sensor. 5. Disconnect the washer hose from the washer pump. 6. Remove the upper bolt from the washer solvent container. 7. Remove the lower bolts from the washer solvent container. 8. Remove the washer solvent container from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Washer Pump/Reservoir Replacement > Page 17172 1. Install the washer solvent container into the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the lower bolts. Tighten Tighten the bolts to 9 N.m (80 lb in). 3. Install the upper bolt. Tighten Tighten the bolt to 9 N.m (80 lb in). 4. Connect the electrical connector to the washer pump. 5. Connect the electrical connector to the washer solvent level sensor. 6. Connect the washer hose to the washer pump. 7. Install the inner wheel housing. 8. Install the battery and battery tray. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Washer Pump/Reservoir Replacement > Page 17173 Windshield Washer Pump: Service and Repair Washer Pump Replacement REMOVAL PROCEDURE 1. Remove the washer solvent container. 2. Remove the washer pumps from the reservoir. INSTALLATION PROCEDURE 1. Install the washer pumps into the reservoir. 2. Install the washer solvent container. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations > Page 17177 Windshield Washer Reservoir: Service and Repair WASHER PUMP/RESERVOIR REPLACEMENT REMOVAL PROCEDURE 1. Remove the battery and battery tray from the vehicle. 2. Remove the inner wheel housing from the vehicle. 3. Disconnect the electrical connector from the washer pump. 4. Disconnect the electrical connector from the washer solvent level sensor. 5. Disconnect the washer hose from the washer pump. 6. Remove the upper bolt from the washer solvent container. 7. Remove the lower bolts from the washer solvent container. 8. Remove the washer solvent container from the vehicle. INSTALLATION PROCEDURE Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations > Page 17178 1. Install the washer solvent container into the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the lower bolts. Tighten Tighten the bolts to 9 N.m (80 lb in). 3. Install the upper bolt. Tighten Tighten the bolt to 9 N.m (80 lb in). 4. Connect the electrical connector to the washer pump. 5. Connect the electrical connector to the washer solvent level sensor. 6. Connect the washer hose to the washer pump. 7. Install the inner wheel housing. 8. Install the battery and battery tray. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Locations View Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 17182 Rear Wiper/Washer And Fog Lamp Switch Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm Replacement Wiper Arm: Service and Repair Wiper Arm Replacement REMOVAL PROCEDURE 1. Mark the position of the wiper blade on the windshield with a suitable marker or a piece of masking tape. 2. Disconnect the washer hose. 3. Remove the cover from the nut on the wiper arm. 4. Remove the nut from the wiper arm. IMPORTANT: Use a battery terminal puller to remove the wiper arm from the drive shaft. 5. Remove the wiper arm from the drive shaft. 6. Clean the knurls of the drive shaft with a wire brush. INSTALLATION PROCEDURE 1. Position the wiper arm so that the wiper blade aligns with the mark made on the windshield before removal. 2. Install the wiper arm onto the drive shaft. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nut on the drive shaft. Tighten Tighten the nut to 30 N.m (22 lb ft). 4. Install the cover on the nut. 5. Connect the washer hose. 6. Clean the locating mark or masking tape from the windshield. 7. Operate the wipers and check for proper operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm Replacement > Page 17187 Wiper Arm: Service and Repair Wiper Arm Replacement - Rear REMOVAL PROCEDURE IMPORTANT: Note the location of the wiper on the glass before removal. 1. Disconnect the washer hose. 2. Swivel the wiper arm cover (1) open. 3. Remove the nut (2) retaining the wiper arm to the wiper motor. 4. Remove the wiper arm from the liftgate. INSTALLATION PROCEDURE 1. Align the wiper arm to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nut (2) retaining the wiper arm to the wiper motor. Tighten Tighten the nut to 23 N.m (17 lb ft). 3. Swivel the wiper arm cover (1) closed. 4. Connect the washer hose to the wiper arm. 5. Check the rear wiper for proper operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance > Page 17192 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement Wiper Blade: Service and Repair Wiper Arm Blade Replacement REMOVAL PROCEDURE 1. Turn the ignition switch to the ACCY position. 2. Set the wiper switch to the PULSE position. 3. Turn the ignition OFF when the wipers are in the innerwipe position and not moving. 4. Push in the button of the wiper blade clip and remove the wiper blade from the inside radius of the wiper arm. 5. Bring the wiper arm out through the opening in the wiper blade. INSTALLATION PROCEDURE 1. Insert the hook of the wiper arm through the opening in the wiper blade. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 17195 2. Position the wiper blade pivot in the inside radius of the wiper arm hook. 3. Pull the wiper blade pivot into the wiper arm hook until the pivot locks into the hook. 4. Operate the wipers and check for proper operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 17196 Wiper Blade: Service and Repair Wiper Blade Element Replacement REMOVAL PROCEDURE IMPORTANT: Replace the wiper blade element if it is removed from the wiper blade. 1. Remove the wiper blade from the wiper arm. 2. Remove the bottom claws (2) of the wiper blade (1) from the notches in the wiper blade element (3). 3. Pull the wiper blade element (3) out through the wiper blade claws (2). INSTALLATION PROCEDURE IMPORTANT: Keep the wiper blade claws in the rubber claw channel of the wiper blade element. Do not allow the claws of the wiper blade to contact the metal spline of the wiper blade element. 1. Insert the open end of the wiper blade element (3) into the bottom claws of the wiper blade (2). 2. Guide the wiper blade element (3) through the wiper blade (1) claw sets. 3. Engage the bottom claw (2) of the wiper blade (1) into the notches in wiper blade element (3). 4. Install the wiper blade onto the wiper arm. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 17197 Wiper Blade: Service and Repair Blade Element Cleaning 1. Lift the wiper blade assemblies off of the windshield glass. 2. Clean the wiper blade element with a clean cloth saturated with full strength washer solution. 3. Rinse the wiper blade assemblies with water. 4. Place the wiper blade assemblies back onto the windshield glass. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 17198 Wiper Blade: Service and Repair Wiper Arm Blade Replacement - Rear REMOVAL PROCEDURE 1. Push in the button of the wiper blade clip and remove the wiper blade from the inside radius of the wiper arm. 2. Bring the wiper arm out through the opening in the wiper blade. INSTALLATION PROCEDURE 1. Insert the hook of the wiper arm through the opening in the wiper blade. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 17199 2. Position the wiper blade pivot in the inside radius of the wiper arm hook. 3. Pull the wiper blade pivot into the wiper arm hook until the pivot locks into the hook. 4. Operate the wipers and inspect for proper operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 17200 Wiper Blade: Service and Repair Blade Element Replacement - Rear REMOVAL PROCEDURE IMPORTANT: Replace the wiper blade element if it is removed from the wiper blade. 1. Remove the wiper blade from the wiper arm. 2. Remove the bottom claws (2) of the wiper blade (1) from the notches in the wiper blade element (3). 3. Pull the wiper blade element (3) out through the wiper blade claws (2). INSTALLATION PROCEDURE IMPORTANT: Keep the wiper blade claws in the rubber claw channel of the wiper blade element. Do not allow the claws of the wiper blade to contact the metal spline of the wiper blade element. 1. Insert the open end of the wiper blade element (3) into the bottom claws of the wiper blade (2). 2. Guide the wiper blade element (3) through the wiper blade (1) claw sets. 3. Engage the bottom claw (2) of the wiper blade (1) into the notches in wiper blade element (3). 4. Install the wiper blade onto the wiper arm. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair Wiper Gear Box: Service and Repair WIPER TRANSMISSION REPLACEMENT TOOLS REQUIRED ^ J 39232 Wiper Transmission Separator ^ J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the wiper arms. 2. Remove the air inlet grille panel. 3. Remove the 4 bolts and the reinforcement panel. 4. Disconnect the electrical connector from the wiper motor. 5. Remove the 2 bolts from the wiper transmission assembly. 6. Remove the wiper transmission assembly from the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Page 17204 7. Remove the drive link from the wiper motor crank arm with the J 39232. 8. Remove the 2 bolts retaining the wiper motor. 9. Remove the wiper motor from the wiper transmission assembly. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the wiper motor onto the wiper transmission assembly with the 2 bolts. Tighten Tighten the 2 bolts to 8 N.m (71 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Page 17205 2. Install the drive link onto the wiper motor crank arm with the J 39529. 3. Install the wiper transmission assembly on the vehicle with the 2 bolts. Tighten Tighten the 2 bolts to 9 N.m (80 lb in). 4. Connect the electrical connector to the wiper motor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Page 17206 5. Install the reinforcement panel with the 4 bolts. Tighten Tighten the 4 bolts to 9 N.m (80 lb in). 6. Install the air inlet grille panel. 7. Install the wiper arms. 8. Operate the wipers and check for proper operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams Windshield Wiper Motor Module Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Replacement Wiper Motor: Service and Repair Wiper Motor Replacement TOOLS REQUIRED ^ J 39232 Wiper Transmission Separator ^ J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the wiper arms. 2. Remove the air inlet grille panel. 3. Remove the 4 bolts and the reinforcement panel. 4. Disconnect the electrical connector from the wiper motor. 5. Remove the 2 bolts from the wiper transmission assembly. 6. Remove the wiper transmission assembly from the vehicle. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Replacement > Page 17212 7. Remove the drive link from the wiper motor crank arm with the J 39232. 8. Remove the 2 bolts retaining the wiper motor. 9. Remove the wiper motor from the wiper transmission assembly. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the wiper motor onto the wiper transmission assembly with the 2 bolts. Tighten Tighten the 2 bolts to 8 N.m (71 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Replacement > Page 17213 2. Install the drive link onto the wiper motor crank arm with the J 39529. 3. Install the wiper transmission assembly on the vehicle with the 2 bolts. Tighten Tighten the 2 bolts to 9 N.m (80 lb in). 4. Connect the electrical connector to the wiper motor. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Replacement > Page 17214 5. Install the reinforcement panel with the 4 bolts. Tighten Tighten the 4 bolts to 9 N.m (80 lb in). 6. Install the air inlet grille panel. 7. Install the wiper arms. 8. Operate the wipers and check for proper operation. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Replacement > Page 17215 Wiper Motor: Service and Repair Wiper Motor Replacement - Rear REMOVAL PROCEDURE 1. Remove the wiper arm. 2. Remove the nut and spacer from the wiper motor shaft. 3. Remove the interior trim panel. 4. Disconnect the wiper motor electrical connector. 5. Remove the two screws. 6. Remove the wiper motor. INSTALLATION PROCEDURE 1. Install the wiper motor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the two screws. Tighten Tighten the screws to 19 N.m (14 lb ft). 3. Connect the wiper motor electrical connector. 4. Install the interior trim panel. 5. Install the spacer and the nut on the wiper motor drive shaft. Tighten Tighten the nut to 8 N.m (71 lb in). Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Replacement > Page 17216 6. Install the wiper arm. Chevrolet K Tahoe 4wd Workshop Manual (V8-5.3L VIN T (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Locations View